Solutionary Chapter 5 y 6

Professional School of Industrial Engineering Estadistic control
CHAPTER 5 EXERCISES
1. When is a process said to be capable or skillful?
The process is said to be capable When the Cpk (CENTRAL TENDENCY

VARIABILITY) is greater than 1.25 FOR AN ALREADY EXISTING
PROCESS IN CASE OF A NEW PROCESS GREATER 1.45
2. Regarding the indices Cp and Cpk, explain:
a) What does the Cp index measure?
Measures the width of the specifications or variation tolerated for the
process with the width of the actual variation:
b) What does it mean for a process to be off-center? Explain with

an example.
It is when the value of the Cpk index is much smaller than the Cp, it
means that the process mean is far from the center of the
specifications. Example:
In a soft drink packaging process, the lower specification EI = 270 ml
and the upper specification ES = 290 ml, with an ideal or nominal
valuation of N = 280. To monitor the correct functioning of the cutting
process, every half hour 5 containers are taken and measured.
According to the measurements made in the last month, where the
process has been working stably, the mean and standard deviation of
the process (population) are μ = 283 and σ = 3, respectively. From
which it stands out that the process
is not centered, since the process mean, μ = 283, is far from the
center of the specifications (N = 280).
c) Does the Cp index take into account the centering of a process?

Explain your answer.
The Cp index does take into account the variability of the process,
because from there the class or category of the process can be
observed.
d) Why is it said that the Cp index measures potential capacity and

the Cpk measures actual capacity? Rely on the previous points
to explain.
With the Cp it tells us if the process has its variability and according
to that it places us in a class or category of the process and the Cpk
index represents the minimum value between the Cpi and Cps, that
is, it is equal to the smallest unilateral index. . And it has the
advantage that it considers the centering of the process
3. If a quality characteristic must be between 30 ± 2, and it is known that

its mean and standard deviation are given by µ = 29.3 and = 0.5,
calculate and interpret in detail the following indices: Cp, Cpk, K, Cr
and Cpm.
EI = 28, ES = 32, μ = 29.3, σ = 0.5
=1.33
It is type 1, it is an adequate process.
= 0.86
Since the process Cpk is less than 1, the process does not meet one of the
specifications.
= -35
Since the value of K is negative, it means that the process average is less
than the nominal value.
The partially adequate value indicating that the process variation potentially
covers 75% of the specification band.
; =0.86
Cpm =0.775
Since the Cpm is less than one, it means that the process does not meet
specifications, either due to centering problems or excessive variability.
4. For exercise 13 of chapter 2, regarding the thickness of the asbestos

sheets, the specifications are: EI = 4.2 mm, ES = 5.8
mm. In addition to the measurements carried out in the last three

months, a process with acceptable stability can be seen, with µ =4.75
and =
0.45. Now answer the following:
a) Calculate the indicator K and interpret it.
b) Obtain the Cp and Cpk indices and interpret them
c) From Table 5.2, estimate the percentage of sheets that do not
meet specifications: on the bottom side, the top side, and both
sides.
d) In summary, does the process meet specifications? Explain your
answer.
EI = 4.2, ES = 5.8, N = 5, μ = 4.75, σ = 0.45.
to) = 31.2%
The process mean is deviated 31.2% to the right of the

nominal value, so the centering of the process is inadequate
and this contributes significantly to the low ability of the
process to meet the upper specification.
b) = 0.59
It belongs to class 4, is not suitable for work, requires

modifications.
= 0.47
The process does not meet at least one of the specifications.

5. The following data represents viscosity measurements from the last

three months of a dairy product. The goal is to have a viscosity of 80 ±
10 cps
a) Build a capacity graph of this process (histogram with
tolerances) and give a first opinion on the capacity.
b) Calculate the mean and standard deviation, and taking these as
population parameters, estimate the indices Cp, Cpk, Cpm and
K, and interpret them in detail.
c) Based on Table 5.2, also estimate the percentage out of
specifications.
d) Should the estimates made in the two previous sections and the
corresponding estimates be viewed with certain reservations?
Because?
Viscosity measurement process capacity

(using 95.0% confidence)
LIE Aim LSE

To process Within
data
LIE 70 General
Aim 80
Capacity (within) potential
LSE 90
Cp 1.22
Sample measurement 82.45
Lower LC 1.03
Sample number 80
Upper LC 1.41
Std Dev (Inside) 2.73813
CPL 1.52
Std Dev (General) 2.62365
CPU 0.92
C pk 0.92
Lower LC 0.76
Upper LC 1.08
General capacity
72 75 78 81 84 87 90
Pp 1.27
Lower LC 1.07
Upper LC 1.47
PPL 1.58
PPU 0.96
P pk 0.96
Observed performance Exp. Inside the performance Exp. Overall performance
PPM < LEL 0.00 PPM < LEL 2.72 PPM < LEL 1.04
PPM > LS E 0.00 PPM > LSE 2913.52 PPM > LSE 2003.12
Total PPM 0.00 Total PPM 2916.24 Total PPM 2004.16
L.
C. lower 0.79
Upper LC 1.13
C pm 0.93
L.
C. lower 0.82
It is type 2, it is a partially adequate process and requires strict control.
= 0.92
Since the process Cpk is less than 1, the process does not meet one of the
specifications.
;
Cpm =0.93
Since the Cpm is less than one, it means that the process does not meet
specifications, either due to centering problems or excessive variability.
6. For exercise 15 in Chapter 2, estimate the capacity indices Cp, Cpk,

and K, and interpret them.
N = 28, ES = 28.5, EI = 27.5, σ = 0.2, μ = 28.11
It is type 3, not suitable for work. An analysis of the process is necessary.

Requires serious modifications to achieve satisfactory quality.
Since the Cpk is less than one, then the process does not meet at least one
of the specifications.
It is a partially adequate value indicating that the process variation

potentially covers 22% of the specification band.
7. An important characteristic in the quality of cow's milk is the fat

concentration. In a particular industry, 3.0% was set as the minimum
standard that the product received directly from dairy farms must
meet. If from the historical data it is known that µ=4.1 and σ=0.38:
a) Calculate the Cpi and interpret it.

b) Based on Table 5.2, estimate the percentage out of specifications.
c) Is the quality satisfactory?
Variable X = fat concentration
to) Cpi = 0.965
Interpretation: since the value is less than 1, then the process does not meet
at least one of the specifications, and for every million units of the product,
1349.69 parts per million do not meet the fat percentage.
b) Interpretation: the percentage that is out of specification would be

0.1350%.
c) The quality of the dairy product is not satisfactory because Cp is

category 3, therefore it requires serious modifications to achieve
satisfactory quality.
8. In exercise 17 of chapter 2, with ES = 6, estimate the Cps index and

interpret it.
Line 1 μ = 6.87, σ = 1.02
Line 2 μ = 7.14, σ = 1.11
Line 3 μ = 7.32, σ = 0.86
9. For exercise 21 in Chapter 2, estimate the Cpi and interpret it.
σ = 1.3, EI =40, μ = 44
= 1.026
Since the value is not greater than 1.25, it is not suitable for the upper part .
10. In a company that produces dairy products, the quality criterion for
the cream is that it has 45% fat, with a tolerance of ± 5. According to
the sampling of recent months, there is a mean of 44.5 with a standard
deviation of 1.3. Perform a capacity analysis to see if the required
quality is met (Cp, Cpk, K, Cpm, real limits). Graphically represent your
results and comment on them.
EI = 40, ES = 50, μ = 44.5, σ = 1.3, N = 45
=1.28
It is class 2, partially adequate, requires strict control.
= 1.15
= -0.1
; = 1.39
Cpm = 1.196
Since the process Cpm is greater than one, it meets the specifications
11. The volume in a packaging process must be between 310 and 330ml.
According to historical data, µ = 318 and = 4. Does the packaging
process work well in terms of volume? Explain your answer.
EI = 310, ES = 330, μ = 318, σ = 4, N = 320
=1.67
It is class 1 and is suitable
= 0.66
Since it is less than one, then the process does not meet at least one of the
specifications.
= -0.2
It is a partially adequate value indicating that the process variation

potentially covers 12% of the specification band.
; = 4.47
Cpm =0.745
Since the Cpm value is less than one, it means that the process does not
meet specifications.
12. The percentage of defective products in a process is 2.3%. Based on

Table 5.2, estimate the Cp of this process.
13. If a process has a Cps = 1.3, estimate the PPM out of specifications
(rely on table 5.2).
If a process has a Cps = 1.3, then parts per million (PPM) = 1349.967.
14. The weight specifications of a preform in a plastic injection process is

60 ± 1g. To make a first assessment of the process capacity, a random
sample of n = 40 pieces is obtained, and it turns out that X = 59.88 and
S = 0.25.
a) Estimate with a 95% confidence level the Cp, Cpk and Cpm
indices, and interpret each of them.
b) Is there assurance that the process capacity is satisfactory?
c) Why was it necessary to estimate by interval?
15. Answer the first parts of the previous problem, but now assume that
the sample size was n = 140. Will the conclusions be the same?
16. Perform problem 14 with n = 40 pieces, X = 59.88 and S 0.15.
17.
18. In problem 24 of chapter 2 we want to guarantee that the percentage of
CO 2 (gas) is between 2.5 and 3.0 by analyzing the data obtained:
a) Calculate the process capability indices, especially K, Cp, and

Cpk, and interpret them.
b) With the evidence obtained, what is your opinion about the
capacity of the referred process?
EI = 3.0, ES = 2.5, μ = 2.65, σ = 0.056, N = 2.75

=1.48
It is class 2 and is adequate.
= 0.89
Since Cpk is less than one, then the process does not meet at least one of
the specifications.
= 40 %
The process mean is 40% deviated to the left of the nominal value, so the
centering of the process is inadequate and this contributes significantly to
the low ability of the process to meet the higher specification.
19. What does it mean for a process to have a three sigma quality level?
Why is that level not enough?
Having a three sigma process means that the corresponding Z index is

equal to three.
20. Explain what the difference is between short-term and long-term

capacity.
Short-term capacity: it is calculated from a lot of data taken during a short

period so that there are no external influences on the process, or with a lot
of data from a long period, but calculating σ with the average range.
Long-term capacity : It is calculated using data taken from a long period for
the process, and σ is estimated by the standard deviation of all the data
(σ=S)
21. Explain the six sigma metric (the Z statistic).
The Z index is used as a metric in Six Sigma when the quality characteristic
is continuous; However, many quality characteristics are attributes.
CHAPTER 6 EXERCISES
Pareto chart
1. Point out the two main objectives of the Pareto diagram.
The two objectives of the Pareto diagram are the stratification and the
verification sheet of a Six Sigma project (identify priorities and cause, since
the different problems that arise in a process are ordered in order of
importance).
2. In a Pareto analysis, a Pareto of problems must first be done and then

a Pareto of causes. Explain what each of these consists of and give a
couple of examples to illustrate it.
Pareto of problems : serves to identify the degree of problems or failures

of a product and know how frequent these problems are.
Pareto of cause : serves to orient exclusively towards the search for the
causes of the problem with the greatest impact, clues about the most
important cause of the problems will be located.
3. What is the Pareto principle? Explain in the context of your work area.
In my work area we install internal networks for natural gas, and to know the
client's compliance we ask questions if there are flaws in the finish,
according to what is mentioned to us, if we make the Pareto diagram, I
would try to correct the problems and the causes of finishing and customer
compliance.
4. Using the data from the valve defects check sheet in Example 6.4, do
the following:
a. perform a Pareto of problems and see which of them is

predominant.
Performing Pareto problems, we observe that “Zone 3” is the predominant

one with 71 defective products.
b. for the most important defect, perform a Pareto for

causes.
Performing Second Level Pareto for “zone 3” and product model “D”, we
noticed that the biggest problem is porosity.
c. In summary, what are the main clues to reduce the

number of defective parts?
In summary, the main clues to reduce the number of defective

parts is in the resistance of the materials due to the porosity of
said parts.
5. In a company in the graphics industry, a record has been kept for two
months of the type of defects that the final products have, and the
following problems were obtained with their respective percentages:
out of tone, 35%: stains, 30%; off-registration, 15%; bad cut, 12%;
opaque barcode, 8%. According to the Pareto principle, can we say
that the vital problem, from a statistical point of view, is out of tune?
Pareto diagram of defects
100 100
80%
80 80
Percentage
60 60
freq
40 VITALS 40
20 20
0 0
defects off tone stains off record Bad cut barcode
freq 35 30 15 12 8
Percentage 35.0 30.0 15.0 12.0 8.0
% accumulated 35.0 65.0 80.0 92.0 100.0
According to the Pareto principle, it can be stated that the Vital problem, from a
statistical point of view, is out of tune with the 35%. In addition to the defect due to
stains and out of registration.
6. List the main activities you do and, according to the time you dedicate
to each of them, make a Pareto.
According to what is related to the day of the week, I dedicate myself to

studying and working, these are my 2 main activities:
According to the Pareto principle, I spend 33.33% working and 20.83% studying
each day.
7. Through an analysis, six basic types of customer complaints were

detected in a company, but each type of complaint caused a different
degree of dissatisfaction or annoyance for the customer. The scale
that was used to measure the degree of annoyance is as follows:
maximum annoyance (10 points), very dissatisfied (8), moderate
annoyance (6), little annoyance (4), very slight (2). Additionally, the
analysis determined the frequency with which the different complaints
occurred in the last semester. The following table summarizes the
results of such analysis:
Type of complaint degree of discomfort frequency of occurrence
TO 4 12%
b 8 5%
c 2 40%
d 6 25%
AND 4 10%
F 8 8%
a. Perform a Pareto analysis to determine what type of

complaint efforts should be directed toward addressing its
causes. Apply recommendation 2 of the Pareto diagram.
8. According to the information from a verification sheet in a line of the

tequila packaging process, in the last month the following results were
presented in terms of defects and frequency:
Packaging defect frequency
Bottle 804
Top 715
Label 1823
Against label 742
Bottle without vigusa 916
Others 102
Total bottles packaged in the month 424654
to. Make a Pareto diagram and draw conclusions.
Packaging Defect Pareto Diagram
5000 100
4000 80
Percentag
frequency
3000 60
2000 40
e
1000 20
0 0
Packaging defect to to the to to either
t
and or
yes l
and and
t
p t
r
EITH
or t or to ER
eithe
iq ig r iq T
t v b t
AND in and
yes to
the t
r
l n
eithe
and r
t c
either
b
frequency 1823 916 804 742 715 102
Percentage 35.7 18.0 15.8 14.5 14.0 2.0
% accumulated 35.7 53.7 69.4 84.0 98.0 100.0
Performing the pareto for problems in the tequila packaging process, we noticed
that in the labeling work it is the first that makes the most errors with 35.73%, while
the second with the most errors is the bottle without vigusa with 17.95%.
9. In a cold meat processing company, through a 100% inspection, problems

were detected in the sausages. Below are the results for one week.
machine shift Problems and package numbers

baler defective
Lack of Stain Stain
empty green yellow
TO Yo 4300 700 700
II 6300 650 650
b Yo 3500 700 400
II 6600 500 420
c Yo 8500 800 324
II 9120 655 345
a. Consider that the severity of the three problems is the same,

perform a Pareto analysis for problems and detect which is
the most significant.
Performing pareto for problems, the problem with the highest level was
detected, which is Vacuum Failure with 38320 defective packages.
b. Regarding the vital problem, make second level paretos

(causes) for both machine and shift.
Makes
Using Second Level pareto for the machines, we notice that “machine C”
performs 16720 defective vacuum failure packets.
c. Perform the previous analyzes again, but considering that

the severity of the problem from the customer's point of view
is as follows: lack of vacuum (6), green spot (10), yellow spot
(8).
Performing second level pareto for the shifts of “machine C”, we notice that
in “shift II” it produces 9120 defective packages, while in “shift I” it produces
8500 defective products.
10. In a manufacturing process, parts become defective for different

reasons. To understand the statistical regularity of this problem, it was
decided to record the inspection data. For the design of the
verification sheet, it is taken into account that the possible sources of
variability (origin of the problems) are the machines, the day and the
shift. The following table shows the data obtained in one week.
a. Perform a Pareto for problems and find which one is

predominant.
b. For the main defect, perform second level paretos on
function of:
(o) superficial scratches, (x) tears, (-) incomplete, (/) inappropriate shape and (*) other .
. Machines.
. Day.
. Shift.
c. Of the second level paretos, which ones were specific clues
found to locate the cause? Explain.
d. In summary, what are the concrete clues to guide improvement
efforts?
11. In a white goods factory there have been problems with the quality of
the washing machines. A quality improvement group decides to review
the problems with the washing machine tub, since it often needs to be
reworked to bring it to acceptable quality. To do this, they stratified the
problems in the washing machine tub by type of defect, with the idea
of locating the main defect. Below is the analysis of the defects found
in the tubs produced in five months. Perform a Pareto analysis and
draw conclusions.
flaw Frequency
Oval tub spout 1200
Deformed perforations 400
chipped tub spout 180
Lack of flux 130
Badly welded 40
total 1950
During the five months, the biggest problems with the inks were due to the
oval ink mouth that generated 1,200 defective products, followed later by
the deformed perforations that generated 400 defective products.
Stratification
12. What is stratification and what is it used for?
Stratification is a quality tool that is used to analyze possible problems,

failures, complaints or data from a certain situation. And it is used to classify
the information collected about a quality characteristic.
13. In the finance area of a company, one of the main problems is bad
checks from customers. Therefore, they hesitate to apply more
vigorous measures with all payments with
checks or only do it with certain clients. How would you use

stratification to make the best decision?
First of all, I would analyze the situation to see where this problem lies, after
having found the negative factor of the current situation, immediately apply
quality criteria, and in this case make sure that all clients are treated equally
with respect to their Payments.
14. In a service area within a manufacturing company, a survey is carried

out to evaluate the quality of the service and the level of customer
satisfaction. The survey consists of 10 questions, and each of them
evaluates different aspects of the service provided. The answers for
each question is a number between 0 and 10. To make a first analysis
of the results obtained, the points obtained from the 10 questions for
each questionnaire are added. Below are the points obtained in 50
quizzes.
78 78 82 85 81 86 80 73 84 78
68 84 75 78 76 76 82 85 91 80
70 87 77 82 84 48 49 39 39 43
35 42 34 44 49 34 30 43 31 34
41 42 45 42 35 38 39 42 43 29
a) Considering that the first 25 questionnaires (ordered by row) come

from one department and the remaining 25 from another, perform a
stratified analysis by department, calculating basic statistics:
mean, median, standard deviation, etc.
Descriptive statistics: Point
Count
Variable total PrcAcum Mean Std.Dev. Variance CoefVar
Minimum Median
point 49 100 60.22 21.13 446.39 35.08
29.0 68.00
N for
Maximum Variable Range IQR Mode fashion Kurtosis Asymmetry
point 91.00 62.00 39.00 42, 78 4 -0.06 -1.80
b) What are your most important observations about the analysis

carried out?
- The total data obtained was 49.

- The average of the 25 questionnaires is 60.22 points.
- 50% of the questionnaires are less than or equal to 68.00 and the other 50%
are greater than or equal to 68.00
- The asymmetry is negative with a value of - 0.06, which means that the
variable takes values that are too low more frequently than very high values
and is asymmetric to the left.
- The units of the maximum difference between extremes between two
variables is 62.00.
- The degree of dispersion of the data with respect to the average value is
21.13.
- The dispersion of its values with respect to the central value of the mean is
446.39
c) When focusing on the department with the biggest problems, would

it be helpful to stratify the data by question? Explain.
In this case it would be advisable to classify the data again to analyze

the problem, failures, complaints or data to classify them according to
the factors that are believed to influence their magnitude, this is done in
order to locate the best way to solve the problem.
15. How would you apply stratification in order to better guide the
strategy to reduce insecurity in a city?
In this case, the first thing to do is to propose different and possible

hypotheses to see where the problem lies. A brainstorming session is
carried out, which may include drug addiction, gang activity, little police
patrolling, very little public lighting, etc. After this we classify all these ideas
in order to locate the best clues to solve the problems and see what is the
cause of this situation.
16. In a company there is a problem of theft of materials, components and

equipment by employees. How would you apply stratification to better
guide the strategy to reduce such thefts?
As a first step, brainstorm, since if it is a company that has three schedules,

the problem could come from the employees who are on the night shift since
there is not as much security control as during daylight hours. What could
be done in this case is to carry out a stricter surveillance control regarding
the raw material storage area, and on the part of the equipment and
machinery, then control this with a reliable and stricter surveillance service. ,
these would be the strategies that would be proposed to try to resolve this
problem.
ALTERNATIVE SOLUTION
verification sheet
17. What are they and what is the purpose of verification sheets?
The verification sheet is a document that is prepared for the purpose of

collecting data based on the observation of the behavior of a process in
order to detect trends, and then analyze the results obtained from a certain
work process or critical situation. . The objectives of the verification sheets
are the following:
- Clearly determine the process subject to observation.
- Define the period of time during which the data will be collected.
- Design a format that is clear and easy to use.
- Obtain data in a consistent and honest way.
18. Point out the different types of verification sheets.
The different types of verification sheets are:

- Type verification sheet: defects and possible causes.
- Process verification sheet (color, size)
- Verification sheet for defective products.
19. Design a check sheet to analyze the thickness distribution of asbestos

sheets, considering that the ideal thickness is 5 mm with a tolerance of
± 0.8. (see example 6.5).
This verification sheet is made according to the defects found in the quality
inspection:
Check sheet for defective products
verification sheet
Product: Date:
Inspector:
Defective due to Frequency Subtotal
Very thin sheets ////////////// 14

out of norm
Poor resistance to heat and /////////// 11

fire
little compressible /// 3
Drilling difficulty // 2
Total 30
20. In a valve factory, in a certain machining area there are three thread-
making machines, which are used by five workers. There have been
problems with the number of defective parts in that area. Managers
pressure workers and blame them for quality problems. The workers,
for their part, tell managers that the machines are too old and that is
why the problems occur. What specifically would you do to clarify the
situation?
In a situation like this, taking into account the quality criteria, we must first of
all brainstorm by collecting data to create a verification sheet, in this case
looking at the different reasons why the number of pieces produced are
defective. , how often these anomalies occur. After having made the
verification sheet, proceed to take corrective actions when you know the
specific reason for the production of excessive defective parts.
21. In a company that manufactures mattresses there are the following

defects: pleating, basting, out of size and stains. The work is done by
means of five machines. Design a check sheet to record defects when
inspection is performed.
check sheet for defective products
verification sheet
Product: Mattresses Date: 12 – 4 - 2011
Inspector: Luis Colonel

morals
Pleated /////////////////// 40
///////////////////
//
Basting /////////////////// 46
///////////////////
////////
Measuring out /////////////////// 69

///////////////////
///////////////////
////////////
stained /////////////////// 94
///////////////////
///////////////////
///////////////////
////////////////
Total 249
- We conclude that we can observe in this verification sheet that the main
defect of the mattresses is the staining at the time of manufacturing.
22. In the tequila packaging process, the main defects are the following:
bottle, lid, label, back label, bottle without vigusa, others. Design a
check sheet to record these defects.
check sheet for defective products
verification sheet
Product: Tequila bottles - packaging Date: 10 – 9 - 2010
Inspector: Jorge
Gonzales Quinones
Bottle // 2
Top /// 3
Label //////// 8
Against label ////////// 10
Bottles without vigusa ///// 5
others //// 4
total 32
- In conclusion for this case we can affirm that the most observed defect is
the back label in the tequila packaging process.
Ishikawa diagram and brainstorming

23. What is the purpose of the Ishikawa diagram?
Pareto chart is made for the purpose of quality improvement to identify and
critically separate the few projects that cause most of the quality problems.
24. What are the different methods of constructing the Ishikawa diagram?
The steps are the following:

- See what the problem is and see what you want to improve and then see
the type of diagram that could be built for the best location of the
problem.
- see the data that will be needed and determine the strategies for solving
the problems.
Dispersion diagram
25. What is the purpose of a scatterplot
It is a graph whose objective is to analyze the way in which two numerical

variables are related, usually measured on the same element of the sample
of a population or process (XY type graph where each element is
represented by a pair of values (x, y ) and a point in the plane.
26. What type of variable goes on the X axis and which goes on the Y
axis?
As the objective is to analyze the relationship between variables, the

following can be cited as an example in a group of students, the relationship
between their height (X) and their weight (Y), or it could also be of interest to
investigate an input variable ( X) of a process with the value of a quality
characteristic (Y) of the final average.
27. If the value of the correlation coefficient between two variables is

close to zero, does it mean that such variables are not related? Explain
your answer.
When the correlation coefficient is equal to or close to zero, it indicates that

there will be no degree of correlation between the variables, since proximity
to zero indicates a practically non-existent linear correlation.
28. In a certain company it is common to pay overtime to meet delivery

times. At this production center, a quality improvement group is trying
to reduce the proportion of bad parts. With
For this purpose, they decide to investigate the relationship that exists
between the amount of overtime, X, and the percentage of defective
items, Y. The data obtained is shown below.
WEEK EXTRA HOURS PERCENTAGE OF DEFECTIVES

1 340 5
2 95 3
3 210 6
4 809 15
5 80 4
6 438 10
7 107 4
8 180 6
9 100 3
10 550 13
11 220 7
12 50 5
13 193 6
14 290 8
15 340 2
16 115 4
17 362 10
18 300 9
19 75 2
20 93 2
21 320 10
22 154 7
a) Obtain the scatterplot for these variables.

Scatter plot of PERCENTAGE DEFECTIVES vs. EXTRA HOURS

16
14
DEFECTIVE
12
10
8
PERCENTA
6
GE
0 100 200 300 400 500 600 700 800 900

EXTRA HOURS
b) What relationship do you see?
A relationship with a low level of correlation is observed because there are

points that are further apart and make the relationship between them
difficult.
c) Based on the above, can you safely include that when working with
overtime, the percentage of defectives increases because factors such
as equipment overheating, worker fatigue, etc. occur, which cause
greater problems in the quality of the parts?
Not necessarily, because we almost always seek to innovate and show

ourselves at the different stages that present changes in profitability and
efficiency.
29. In a paint factory we want to reduce the varnish drying time, the
following data correspond to the varnish drying (hours), and the
amount of additive with which we want to achieve such a reduction.
ADDITIVE CONTENT DRYING TIME

1 14
2 11
3 10
4 8
5 7.5
6 9
7 10
8 13
9 12
10 15
a) Using a scatter diagram, investigate the relationship between drying

time and the amount of additive.
Scatter plot of DRYING TIME vs. ADDITIVE CONTENT
15
14
IN DRYING
13
12
11
TIME
10
7
0 2 4 6 8 10
ADDITIVE CONTENT
relations
b) Based on the hip, around what additive amount
Would you recommend to reduce drying time?
There is a large amount of additive that we would have to
change.
correlation
c) Get the coefficient of between both variables and
interpret it.
d) Apparently the linear correlation coefficient is very low. Do you mean

that the drying time is not related to the amount of additive?
That's right, since our correlation coefficient is low, it is an indicator that

there is no type of relationship between the amount of additive and the
drying time.
32. In an industry we want to investigate how temperature (ºC) influences

the vapor pressure of B-trimethylboron. The data obtained for this
purpose is shown below:
PRESSU
TEMPERATURE RE
13 2,9
19,5 5,1
45,7 30,5
56,1 51,4
64,4 74,5
71,4 100,2
8035 143,7
85,7 176,9
a) Build a
22,5 8,5
diagram of
27,2 10,3
dispersion and
31,8 14,6
interpret it.
As we noted, in the graph, the more the temperature increases, the

pressure also increases in the B-trimethylboron industry. This indicates that
the curve has a positive and increasing slope, and that there is a degree of
relationship between the 2 variables.
b) Obtain the correlation coefficient and when interpreting it,

compare what was observed with part a)
Regression analysis: TEMPERATURE vs. PRESSURE

The regression equation is
TEMPERATURE = 24.3 + 0.405 PRESSURE
Correlations: TEMPERATURE, PRESSURE

Pearson correlation of TEMPERATURE and PRESSURE = 0.948
P value = 0.000
Just as we denoted in the interpretation of the graph above, the correlation

coefficient indicates that there is a high degree of relationship between our studied
variables, and in this way with the regression equation, it indicates the degree of
increase that a depending on the other.
33. As part of the analysis of the absenteeism problem, you decide to

investigate the relationship between the employee's age and the days
missed from work in the year. Data for the last year is shown below.
employee age faults employee age faults

1 29 6 21 25 7
2 33 5 22 38 3
3 40 0 23 22 0
4 23 8 24 30 4
5 31 6 25 24 7
6 20 9 26 39 10
7 30 5 27 35 5
8 38 5 28 20 1
9 23 8 29 32 5
10 25 6 30 25 5
11 26 7 31 36 5
12 30 5 32 30 5
13 42 2 33 20 10
14 34 5 34 38 4
15 31 6 35 39 4
16 18 11 36 34 4
17 33 6 37 35 6
18 33 4 38 27 7
19 33 5 39 40 3
20 32 5 40 31 6
a) Using a scatter diagram, analyze the relationship between these two

variables.
As we noted, there is no particular relationship between our variables, but a

random pattern exists between them.
b) What type of relationship do you observe and what are some special
facts?
A simple relationship is observed, which can be interpreted using a

regression to observe future values and trends in our data.
Regression analysis: Age vs. Fouls
The regression equation is

Age = 36.9 - 1.18 Fouls
c) Calculate the correlation coefficient and interpret it.
Pearson Correlation of Age and Absences = -0.442

P Value = 0.004
The correlation coefficient in our case is a small value which indicates that there is
not a high degree of relationship between our variables, a detail that was observed
in the graph, therefore the relationship between our variables is not very strong.
Process diagrams
34. What is a flowchart and what is it useful for?
The Flowgram or Flow Diagram consists of graphically representing events,

situations, movements or relationships of all kinds, by means of symbols.
Below, the concept of Flowcharts or Flow Diagrams, characteristics, types,
symbology, design and elaboration will be observed from three different
authors.
According to Gómez Cejas, Guillermo. Year 1997; The Flow grama or Flux
grama, is a diagram that graphically expresses the different operations that
make up a procedure or part of it, establishing its chronological sequence.
Depending on its format or purpose, it may contain additional information
about the method of execution of operations, the itinerary of people, the
forms, the distance traveled, the time spent, etc. According to Chiavenato
Idalberto. Year 1993; The Flow Chart or Flow Diagram,
is a graph that represents the flow or sequence of simple routines. It has the
advantage of indicating the sequence of the process in question, the units
involved and those responsible for its execution.
35. Make a flowchart for the process of making good coffee
The diagram to prepare a good coffee is as follows:

START
ADD WATER
ADD COFFEE
WANTS ADD
Y
E
A
H
MILK? MILK
NO
WANTS ADD
Y
E
A
H
SUGAR? SUGAR
NO
COFFEE
PREPARED
END
36. What is a PEPSU diagram and what is it useful for?
This tool is useful for defining the start and end of the process by facilitating the
identification of its suppliers, inputs, subprocesses, outputs and users.
The acronym PEPSU

They represent:
Suppliers: Entities or simply people who provide the

an
tickets as materials, information d others Supplies.
They are the materials, information and

Tickets: others supplies necessary for
operate
the processes. Entry requirements must be defined, and
you must verify that the inputs satisfy them. It may be the case that there is one or
more entries for the same process.
Process: A process is a set of mutually related or interacting activities, which

transform input elements into results.
Users: These are the organizations or people who receive a product. The user (or
client) can be internal or external to the organization.
The definition of the process is carried out in the opposite direction to the
presentation of the PEPSU (Users Outputs-Process-Inputs-Suppliers), that is, it
must start with the users column. To identify the users of the process, it is
recommended to list the users and verify if they are actually the ones receiving the
work or service and if there are users who have not been considered.
37. Make a PEPSU diagram for the process of making good coffee
Q HIS
PE
WANTS WANTS COFFEE EN

START ADD WATER ADD COFFEE NO NO D
MILK? SUGAR? PREPARED
YEAH
YEAH
ADD ADD
MILK SUGAR
SUGAR
MILK
38. What is a process mapping and what is it useful for?
 Process Mapping is one of the improvement techniques proposed by Lean

Manufacturing. It is a graphic representation of a process, showing the
sequence of tasks to be performed and their trajectory.
 An easy way to understand the management of processes for all company

personnel is through the design of a process map, which represents the
particular or specific situation of the organization and where primarily the
interrelationships of the processes are identified as a mechanism. to
improve internal communications, which are normally deficient due to not
knowing what products and requirements internal clients require and even
more serious, when the needs of external clients, who are the ones who
pay for the services and products, are unknown.
 First of all, a process map must be defined, which will become the
gateway to the world of processes within companies. Making an analogy to
the world of the Internet, the process map is like the home page of a web
portal. From then on, orientation and navigation through each of the
processes will be easier.
39. Make a process mapping for making a pizza, writing down the output
variables of the final product that you consider the most important, as
well as the input variables at the stage in which the pizza is placed in
the oven.
Quality display function
40. What is the objective of the DFC?
It allows you to focus on the details, whether products or services, that lead to
market success.
It helps concentrate energy on high-risk details that almost always go unnoticed
and allows the normal operating system to handle a multitude of details,
Most importantly, DFC is a tool to identify and satisfy customer needs, to
manufacture quality and cost oriented products in an era where these are the
factors that lead to increasing market share.
41. Draw the general shape of the house of quality, and briefly describe
the information that goes into each of its parts.
QFD structure:
The most used analogy to explain how the QFD is structured is a house. The wall
of the house on the left side, component 1, is the client's input. This is the stage in
the process in which the customer's requirements related to the product/service are
determined.
To satisfy customer requirements, the producer works to certain performance

specifications, and asks its suppliers to do the same. This is the interior roof of the
house or component 2. One of the questions that the QFD process will answer will
be the following: Are our current manufacturing requirements sufficient to meet or
exceed customer requirements?
The right wall of the house, component 3, is the planning matrix. This is the
component most widely associated with QFD. The planning matrix is the
component that is used to translate customer requirements into plans to meet or

exceed those requirements. It includes marking customer requirements in one
matrix, and manufacturing processes in another, prioritizing customer
requirements, and making decisions related to necessary improvements in
manufacturing processes.
The center of the house, component 4, is where customer requirements are

converted into manufacturing terms or expressions. If a customer wants the
operating life of their product to be twelve months instead of six, what does this
mean in terms of the materials used? Design? The manufacturing processes?
These types of questions are answered in this component.
The bottom or base of the house, component 5, is where the process requirements
that are critical are prioritized. Which manufacturing requirement is most important
in terms of meeting or exceeding customer requirements? What is next, and so
on? Each hierarchical process requirement receives a score that represents its
level of difficulty or how difficult it is to achieve.
The exterior roof of the house, component 6, is where the trade-offs are identified.
These are trade-offs that have to do with the producer's requirements. Given your
customer's requirements and your manufacturing capabilities, what is the best
thing the organization can do? This type of question is answered here. This is the
main structure of a QFD array.
42. How is the priority or importance of the hows obtained?
The how is the characteristic of the process. We will obtain the hows by
giving solutions to the needs and expectations of our clients in consultation
and from their responses with the “whats”, thus, it could be said that the
hows are obtained with the help of the whats.
43. Answer the following items. Suppose that you are going to design a
pizza to your liking and that you will use the DFC to do so.
a) Make a list of the main features you would expect when eating
pizza at a restaurant (think pizza and service).
b) Write down this list on the blank form of the DFC. Which is in
figure 6.19 (in the whats area).
c) Assign priorities to the list above, use the scale of 0 to 5.
d) Think about each what and make a list of the hows you think are
necessary to address those whats, and write them down in the
form in Figure 6.19.
e) Get the relationships between the whats and the hows.
f) Get the importance and relative importance of the hows.
g) What are the two hows of a pizza that most influence your
satisfaction?
44. What is the main purpose of a poka-yoke system?
The purpose of Poka-yoke is to eliminate defects in a product, either

preventing or correcting errors that arise as soon as possible.
The concept is simple: if errors are not allowed to occur on the production
line, then quality will be high and rework little. This increases customer
satisfaction and decreases costs at the same time. The result is high value
for the client. Not only is the concept simple, but usually the tools and/or
devices are simple as well.
Poka Yoke
45. Explain the origin and meaning of the words poka-yoke
Understanding that this term offended many workers, Sigeo Shingo developed
the term Poka Yoke. Translated as “fail-proofing” or “fail-safing.” The literal
meaning is: Avoiding (yokeru) unintentional mistakes (poka). The idea of this
Poka – Yoke technique is to respect the intelligence of the workers. A poka-
yoke (Japanese ポカヨケ , literally mistake-proof) is a device (generally)
intended to prevent mistakes; Some authors handle poka-yoke as an anti-fool
system which guarantees the safety of the machinery before the users, process
or procedure, in which they are related, in this way, not causing accidents of
any type; originally that poorly manufactured parts continued in process with the
consequent cost.
Ex:
The USB connector is a poka-yoke that does not allow you to connect it
backwards.
46. Point out the two main types of poka-yoke devices and explain what
each is made of.
47. Provide some examples of devices that comply with the poka-yoke
device philosophy.
Example: Real fact: An example of millions of dollars lost due to an

avoidable error due to poka Yoke has been offered by NASA. Due to the
reverse placement of a switch, the Genesis probe did not open its parachute
upon returning to Earth and crashed. If the switch was designed in such a
way that it was impossible to fit backwards, this accident would not have
occurred. Another real and recent case is that of the administration of
porridge to a newborn baby through a route directed to the bloodstream
instead of through the route to the stomach: the connections were the same.
The entry of food directly into the blood caused death due to multiple organ
failure in the baby. If the connections had been incompatible, human error
would not have been possible.
Higher Technological Institute of Lerdo.
48. Do poke-yoke mechanisms only prevent human errors? Explain your

answer.
Yeah. We can determine it by the following lemma. “People are animals that
forget. Seek to learn more of what you forget”
The fact is that human beings are very forgetful, and we tend to make
mistakes and it is very common to blame people for making mistakes.
Particularly at work, this attitude not only demotivates and lowers the morale
of workers, but it does not solve the problem. Poka Yoke is a technique that
helps avoid human errors at work.
49. Explain the meaning of “do inspection at the source” in the poka-yoke
context
Check the factors that cause errors, not the resulting defects. It could be
said that in the company this factor occurs in 60%.
50. Who is credited as the creator of the idea of poka-yoke devices?
Poka-yoke is a quality technique developed by Japanese engineer Shigeo

Shingo in the 1960s, which means "mistake-proof." The main idea is to
create a process where errors are impossible to make. Shigeo Shingo was a
specialist in statistical process control in the 1950s, but became
disillusioned when he realized that he would never be able to reduce defects
in his process to zero. Statistical sampling implies that some products are
not reviewed, so a certain percentage of error will always reach the final
consumer.
51. In a manufacturing process, after performing a certain operation on a

cylindrical container, an operator must place it face up on a conveyor
mechanism. However, sometimes, due to the worker's carelessness,
he makes the mistake of putting the piece upside down, which
subsequently causes a quality problem in the next operation.
a) Why is the strategy of insisting or pressuring the operator

insufficient to avoid the error described above?
b) What is the cause or source of the error?
c) Propose different poka-yoke devices that allow 100% inspection
at the source of error. For each device you propose, make the
considerations on which such mechanism would be ideal.
52. A person must attach a label to a box containing a target in order to

notice its correct position. However, sometimes he makes a mistake
and puts the label backwards.
a) Why is the strategy of insisting or pressuring the person to place

the label correctly insufficient to avoid the error?
b) What is the cause or source of error?
c) Propose different poka-yoke devices that allow eliminating or
reducing the error

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Professional School of Industrial Engineering Estadistic control

1. When is a process said to be capable or skillful?

The process is said to be capable When the Cpk (CENTRAL TENDENCY

2. Regarding the indices Cp and Cpk, explain:

a) What does the Cp index measure?

Measures the width of the specifications or variation tolerated for the

process with the width of the actual variation:

b) What does it mean for a process to be off-center? Explain with

c) Does the Cp index take into account the centering of a process?

d) Why is it said that the Cp index measures potential capacity and

3. If a quality characteristic must be between 30 ± 2, and it is known that

EI = 28, ES = 32, μ = 29.3, σ = 0.5

It is type 1, it is an adequate process.

4. For exercise 13 of chapter 2, regarding the thickness of the asbestos

mm. In addition to the measurements carried out in the last three

EI = 4.2, ES = 5.8, N = 5, μ = 4.75, σ = 0.45.

The process mean is deviated 31.2% to the right of the

It belongs to class 4, is not suitable for work, requires

The process does not meet at least one of the specifications.

5. The following data represents viscosity measurements from the last

Viscosity measurement process capacity

LIE Aim LSE

It is type 2, it is a partially adequate process and requires strict control.

6. For exercise 15 in Chapter 2, estimate the capacity indices Cp, Cpk,

N = 28, ES = 28.5, EI = 27.5, σ = 0.2, μ = 28.11

It is type 3, not suitable for work. An analysis of the process is necessary.

It is a partially adequate value indicating that the process variation

7. An important characteristic in the quality of cow's milk is the fat

a) Calculate the Cpi and interpret it.

Variable X = fat concentration

to) Cpi = 0.965

b) Interpretation: the percentage that is out of specification would be

c) The quality of the dairy product is not satisfactory because Cp is

8. In exercise 17 of chapter 2, with ES = 6, estimate the Cps index and

Line 1 μ = 6.87, σ = 1.02

Line 2 μ = 7.14, σ = 1.11

Line 3 μ = 7.32, σ = 0.86

9. For exercise 21 in Chapter 2, estimate the Cpi and interpret it.

EI = 40, ES = 50, μ = 44.5, σ = 1.3, N = 45

It is class 2, partially adequate, requires strict control.

EI = 310, ES = 330, μ = 318, σ = 4, N = 320

It is class 1 and is suitable

It is a partially adequate value indicating that the process variation

12. The percentage of defective products in a process is 2.3%. Based on

14. The weight specifications of a preform in a plastic injection process is

16. Perform problem 14 with n = 40 pieces, X = 59.88 and S 0.15.

a) Calculate the process capability indices, especially K, Cp, and

EI = 3.0, ES = 2.5, μ = 2.65, σ = 0.056, N = 2.75

It is class 2 and is adequate.

Having a three sigma process means that the corresponding Z index is

20. Explain what the difference is between short-term and long-term

Short-term capacity: it is calculated from a lot of data taken during a short

21. Explain the six sigma metric (the Z statistic).

2. In a Pareto analysis, a Pareto of problems must first be done and then

Pareto of problems : serves to identify the degree of problems or failures

a. perform a Pareto of problems and see which of them is

Performing Pareto problems, we observe that “Zone 3” is the predominant

b. for the most important defect, perform a Pareto for

c. In summary, what are the main clues to reduce the

In summary, the main clues to reduce the number of defective

Pareto diagram of defects

According to what is related to the day of the week, I dedicate myself to

7. Through an analysis, six basic types of customer complaints were