JANUARY 2022

INSTRUCTION: There are TWO (2) questions in this booklet.

Question 1

(a) A Pareto Chart is one of the most useful tools during MEASURE stage in DMAIC
(Define-Measure-Analyze-Improve-Control). It is used to graphically summarize and
display the relative importance of the differences between groups of data. Table 1
shows the data on the occurrences of up to 10 defects. Construct a Pareto Chart
using the data in Table 1.
(16 marks)
Table 1: Types of defects
Defects Count
Dimensional deviation 190
Corrosion 185
Short circuit 170
Tools marks 100
Wrong part number 50
Wrong part 44
Late delivery 37
Transportation damage 28
Missing chamfer 19
Surface finish not OK 7

(b) Scatter Diagram is one of the tools used during ANALYZE phase in DMAIC. It is
used to study possible relationship between two (2) variables. Construct Scatter
Diagram based on Table 2 which shows the data of nonconformities versus the total
number of parts produced per day. Identify the relationship between the two (2)
variables involved.
(9 marks)

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Table 2: Nonconformities (NC) versus the total number of parts (n) produced
per day
No. NC n No. NC n
1 12 100 11 20 110
2 8 80 12 15 120
3 6 80 13 9 120
4 9 100 14 8 120
5 10 110 15 6 110
6 12 110 16 8 80
7 11 100 17 10 80
8 16 100 18 7 80
9 10 90 19 5 90
10 6 90 20 8 100

(c) The data shown in Table 3 are and R values for 25 samples of size n=5 taken from
a process producing bearings. The measurements are made on the inside diameter
of the bearing.
i. Determine the upper and lower control limits (UCL & LCL) and the overall

means ( X & R ) for -chart and R-chart.

Sample X R Sample X R
Number Number
1 34.5 3 14 34.0 6
2 34.2 4 15 37.1 5
3 31.6 4 16 34.9 7
4 31.5 4 17 33.5 4
5 35.0 5 18 31.7 3
6 34.1 6 19 34.0 8
7 32.6 4 20 35.1 4
8 33.8 3 21 33.7 2
9 34.8 7 22 32.8 1
10 33.6 8 23 33.5 3
11 31.9 3 24 34.2 2

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12 38.6 9 25 33.3 2
13 35.4 8

ii. Draw the X and R-chart charts and plot the values of the sample means and
ranges.
(16 marks)
iii. Do the data indicate a process that is in control? Justify your answer.
(3 marks)

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Question 2

(a) Process capability (PC) studies are carried out to compare customer requirements
with process performance.
i. Explain when usually PC studies will be carried out.
(2 marks)
ii. Describe the characteristics of inherent capability. State two (2) points.
(4 marks)
iii. With simple sketching, explain the characteristics of a process with Cp = 1.33.
(4 marks)

(b) Lucky’s Chicken advertises healthy chicken with 20% fewer calories. The process
average distribution for healthy chicken breasts is 530 calories., with a standard
deviation of the population of 40 calories. Lucky’s randomly takes samples of ten
chicken breast to measure calorie content. The product design calls for the average
chicken breast to contain 500 ± 50 calories. Calculate the process capability index
(target 1.33) and the process capability ratio. Interpret the results.
(9 marks)

(c) The Toyota Production System (TPS) organizes manufacturing and logistics for the
automobile manufacturer, including interaction with suppliers and customers.
i. State the main objective of the TPS.
(2 marks)
ii. State two (2) of the fundamentals in Lean process.
(2 marks)
iii. Distinguish the effects of Lean between organizations and customers. State
three (3) points.
(6 marks)

(d) A Kanban is an indicator, or a signal, that workers need more material in a production
process. The material may come from sub-assemblers within a facility or from
outside suppliers.
i. Explain five (5) of the Kanban rules.
(10 marks)
ii. Explain briefly the procedure of Kanban.
(5 marks)

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iii. Calculate the number of Kanban in a system using the following data in Table
4.
(6 marks)
Table 4

Daily demand 500 cakes

Lead time 2 days

Safety stock ½ day

Kanban container size 250 cakes

END OF FINAL EXAMINATION

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