ASSIGNMENT #7

IE 323 Spring 2013

Due Date: Wed., 4/17 in class Textbook: p. 575-576 p. 609 p. 706-707 1, 5 1, 2 2,3,4

1. The results of an experiment involving a storage battery used in the launching mechanism of a shoulder-fired ground-to-air missile were presented. Three material types can be used to make the battery plates. The objective is to design a battery that is relatively unaffected by the ambient temperature. The output response from the battery is effective life in hours. Three temperature levels are selected, and a factorial experiment with four replicates is run. The data is listed in the table below: Temperature (F) Medium 34 40 80 75 136 122 106 115 174 120 150 139

Material 1 2 3

Low 130 155 74 180 150 188 159 126 138 110 168 160

High 20 70 82 58 25 70 58 45 96 104 82 60

(a) State the appropriate hypotheses for this case. Do so by using both words and notation. (b) Construct the ANOVA table to test for main effects and interactions. Use = 0.05 for the tests. Which factor(s), if any, are significant? (c) Draw a graph that represents the (possible) interaction effect. (d) Based on the significant effects, comment on how material type and temperature affects the effective life. If there are any significant effects, make a recommendation as to which factors or combination produces the higher life values. 2. A replicated 23 experiment was conducted to estimate the effects of three factors on the yield of a chemical reaction. The factors were A: catalyst concentration (low or high), B: reagent (standard formulation or new formulation), and C: stirring rate (slow or fast). Three replicates were obtained for each treatment. The yields are measured as a percent of a theoretical maximum. A + + + + B + + + + C + + + + Treatment (1) 71.67, a 78.46, b 77.14, ab 79.72, c 72.65, ac 80.10, bc 80.20, abc 75.58, Replicates 70.55, 67.40 75.42, 81.77 78.25, 78.33 76.17, 78.41 71.03, 73.54 73.91, 74.81 73.49, 74.86 80.28, 71.64

(a) Draw the corresponding cube with the design points. Label the points with the appropriate notation. (b) Produce a complete test matrix which includes calculations for contrast, effect and sum of squares. (c) Construct the ANOVA table. Which effects are significant at = 0.05? (over)

3. A quality engineer applied control chart methodology to the manufacturing of a horseshoe-shaped metal fastener called a robotics clamp. Users of the clamp were concerned with the width of the gap between the two ends of the fastener. Their preferred target width is 0.054 inches. An optical measuring device was used to measure the gap width of the fastener during the manufacturing process. The manufacturer sampled five finished clamps every 15 minutes throughout its 16-hour daily production schedule and optically measured the gap. Data for 4 consecutive hours of production are presented in the following table. Gap Width (thousandths of an inch) _____ 54.1 53.9 54.0 53.8 53.7 54.1 54.4 55.1 55.2 53.1 55.9 54.5 53.4 52.9 53.0 52.7 51.9 52.6 53.4 51.7 55.0 54.0 53.8 53.6 56.6 53.1 52.9 54.0 57.2 54.5 51.6 54.3 56.3 55.2 56.1 54.0 53.1 52.9 56.3 55.4 51.0 56.3 55.6 54.2 54.2 55.8 53.8 52.1 57.5 55.4 54.0 53.1 56.9 54.0 55.1 54.2 53.9 54.0 54.6 54.8 56.1 55.1 55.0 54.0

Time 00:15 00:30 00:45 01:00 01:15 01:30 01:45 02:00 02:15 02:30 02:45 03:00 03:15 03:30 03:45 04:00

54.2 53.9 54.0 52.1 53.0 54.2 55.2 53.3 54.9 55.7 55.2 54.2 55.7 53.7 54.1 53.5

(a) The quality engineer is trying to establish the control limits for an X and R chart. Using the data, compute the centerline and control limits for an R chart. Plot the points. Is the process in statistical control? (b) Compute the centerline and limits and draw the X chart. Does the process mean appear to be in control? (c) Assume that the assignable cause for the out-of-control point(s) is found and corrected. Eliminate the out-of-control point, recompute the limits and redraw both the R chart and the X chart. Does the process appear to be in control now? (d) Once the process is in control, estimate the mean and standard deviation for the process. (e) Specifications require the gap width of a clamp to fall within 54 4 thousandths of an inch. Estimate the fraction nonconforming number of clamps. (f) Estimate the Cp and Cpk. Comment on their results.