SQC New Data

2011-2012
Statistical Quality Control
Mr.VAIBHAV VITHOBA NAIK MECHANICAL ENGINEERING S.S JONDHALE COLLEGE OF ENGINEERING
Industrial Engineering & Enterprise Resource Planning
Statistical Quality Control
1. Cost of quality 2. Quality specification 3. Need of SQC 4. Concept of variation 5. Central tendency theorem 6. Acceptance Sampling 7. Control chart for variable 8. Control chart for attributes 9. TQM
Vaibhav Vithoba Naik
SQC 1. Short note a. b. c. d. e. f. g. Cost of quality **** Quality of design Quality of conformance AQL AOQ LTPD Process capability ** 5 m
2. Differentiate between the defect and defectives ?5m** 3. What do you understand by process capability with suitable example.explian the concept of the process capability?8m 4. Explain process capability 10 m 5. What is the process chart? Explain the various types ?10m 6. Explain the different quality standard in brief? 7. Discuss the ISO QUALITY standard .state its at least of 10 clauses? 8. Define quality standard.Disccuss the various quality standard in details with its causes?10m 9. Define control chart? Diffrent between the variable control chart and attribute control chart in details with example? 10. Explain the different type of control chart in SQC 11. Comment on control chart and control limit? Different between the variable control chart and attribute control chart ? 12. What do you mean by quality standard 5m 13. Write a note on TQM policy and objectives?4m
Q.1: -Short notes on Cost of Quality? Solution: COST OF QUALTIY The expenditure incurred to improve the quality of the product is generally termed as Cost of Quality. The cost of carrying out the companys quality function i.e meeting the quality needs of the customers are known as Cost of Quality. These includes 1. Market research cost. 2. The product R and D costs. 3. Cost of inspection and tests 4. Cost defects prevention. 5. Cost of scrap, quality failure. 6. Cost of QA (Quality assurances) 7. Cost of field service. 8. Design Costs.
Objectives of the Evaluation of the COST OF THE QUALITY 1. To identify the major opportunities for cost reductions. 2. To identify the opportunities for reducing cost reduction. 3. To expand the budgetary and cost control. 4. To collect the quality data which is affecting in the poor quality of the product.
Quality specification
1) The concept of designing a component means finalizing the dimension of give jobs by considering the stress calculation. 2) When after calcaulations,the design conclusion are explains on papers ,called as Quality specification. 3) The specification contains the list of essential characteristics and their tolerances. 4) The quality specification include Material specification Process specification Method of testing Criteria of acceptance and rejection. Method of use.
5) One specification may or may not be sufficient to describe the product. 6) The specification are classified as
a. The standard specification :

The standard bodies formulate the specification for standardization of the components. Example specification by BIS.
b. Consumer specification:
When BIS specifications are not available or not suitable for the particular customer need, then consumer specification are used.
c. Company specifications :
When a company which manufacture produce its own specification ,called as company specifications.
Q.1 Describe Different Quality Specification? Solution:Quality Specification 1. Quality Specification is the process to define the requirement of quality characteristics 2. Quality Specification contains a list of essential characteristics and tolerances 3. It may includes a. Material specification b. Process specification c. Method of testing d. Criteria of acceptance and rejection. e. Method of use. f. Programmes.
Need of Specification 1. Helps the manufacturing department to decide what exactly is to be produced. 2. To decide the raw material, process equipment, skill required to produce the product of designed quality. 3. Top differentiate between defectives and non defective parts. 4. To decide the inspection and testing standards required. 5. To judge the various requirement of the buyer. 6. To plan the various manufacturing facilities.
Types of Specification 1. Standard specifications. 2. Consumer Specifications. 3. Company Specifications. 4. Process Specifications 5. Test Specifications.
1. Standard specifications.
a. Most of the countries have their own standard bodies. b. These standard bodies formulate the specification for a variety of product. c. In India, BIS is Nations Standard Body. 2. Consumer Specifications. a. When the BIS specifications are not available or suitable for particular customer needs, then the manufacture manufactures the product according to the customer needs and specifications. b. These specifications are called Consumer Specifications. 3. Company Specifications. a. When the manufacture the product according own specifications to suit the customer needs, they are called as the company specification. 4. Process Specifications a. It is essential to specify the process to manufacture the particular product with specified quality. b. The process specification fulfillment is fulfillment of the product quality. c. It includes Specifications identifications. Material requirement. Sequence of operation. Process sheet Process condition (temp,pressure and humidity) Inspection and testing standards.
5. Test Specifications.
The test specifications includes a. The various specifications about the testing methods. b. Instrument and testing equipment required for testing with specification.
c. Method of selection the testing method and the preparation of sample specimens. d. Testing procedure. Q.1.Explain Quality of Design? Solution:Quality of Design 1. The quality of design is related with the tightness of the specification which are used for manufacturing of a product. 2. If the specification required for product is according to the national and international standards, then the product is said to have good quality of design. 3. A product having work tolerance of 0.01 mm is having better quality than the product having work tolerance of 0.001mm. Factor affecting /controlling the Quality of Design 1. Types of customers in the market. 2. Performance of product expected. 3. Profit considerations. 4. Changing needs. 5. Economic Considerations. 6. Feasibility. Q.2.Explain Quality of Confirmation? Solution:Quality of Confirmation 1. The quality of conformance is concerned with how well the manufactured product conforms the quality of design. 2. All the products should be conformed to the designed specifications. 3. The product which is fulfilling the designed specifications and providing a good quality then it is said to have a good quality of conformance. Factor affecting /controlling the Quality of Conformance 1. Adequate quality of raw material, machineries, tools and equipment, inspection and testing equipments. 2. Proper process and adequate process control.
3. Quality of operators in regards to their skill and experience. 4. Inspections stages and frequency of inspections. 5. Proper storage and finished product. Q.3.Short notes on Quality of Performance? Solution:Quality of Performance 1. Quality of performance is concerned with how well a manufactured product gives its performance. 2. It depends on Quality of design and Quality of performance. Example: If a centrifugal pump lifts the water to the desired height then we say the quality of performance of centrifugal pump is good. 3. The quality of design can be very good but if proper quality control is not there, quality of conformance is poor, This will result into poor quality of performance also as the product will fail to satisfy customer. 4. Also if the quality of design is poor then the quality of performance will be affected still the quality of performance is good. 5. Thus for a good quality of performance, both quality of design and quality of conformance should be good.
Q.3.What is Quality Characteristics? Explain any one of them? OR What are the main elements of Quality Function? Solution:Main Elements of Quality Function The three main elements of the quality function 1. Acceptance function 2. Prevention function 3. Assurance function 1. Acceptance function a. This is the day to day job of measuring the product, judging the performance, making disposition and recoding the data. b. It cam include the incidental function as mainting, measuring equipment storage, salvage. c. This function is related to the acceptability of the product with regard to the set quality of programme. 2. Prevention function a. This function includes the quality control in its various aspects, economic studies, process capability studies, design of experiments, design of sampling plans. b. In this function, the different measure is taken to control the quality of products by minimizing the defects. 3. Assurance functions a. This is high level job of preparing the executive type information on quality presenting it to the various interested supervisory levels.
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Q.1 Define SQC & State its benefits. Solution:Statistical quality control: A quality Control system is called SQC, when statistical techniques are employed to control the quality or to solve quality problems. It is based on law of large numbers & Mathematical theory of probabilities. Modern techniques of SQC & acceptance sampling have an important role in improvement of quality, enhancement of productivity, creation of consumer confidence & development of industrial economy of country. Advantages/Benefits of SQC: 1) Efficiency & Cost reduction 2) Reduction of scrap:- It enables to forecast troubles before rejection occur & reduce the amount of spoiled work. 3) More effective pressure. 4) Easy detection of faults. 5) Easy application. 6) Reduction in consumer complaints. 7) Quality awareness creation in employees. 8) Improves productivity. 9) Reduce wastage of men & machines hours.
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Q.2. Why statistics is important in Quality Control? State the benefits of SQC? Solution:STATISTICAL QUALITY CONTROL: 1) It is the branch of quality control which deals with collection, problem analysis and interpretation of data to solve the problem. 2) Statistical quality control applies the law of statistics to solve quality control problem. 3) It is based on the law of application to large number and theory of probability. IMPORTANCE OF STATISTICAL QUALITY CONTROL 1. Less amount of inspection Due to SQC, less amount of inspection is required which saves the lot of man hour of the production 2. Reduction in scrap and reworking Due to SQC techniques of production, production is possible with minimum chances of scraps and reworks. 3. Fault fining and corrective action Due to SQC, the fault finding is easy and the corrective action can be easily taken 4. Efficiency and cost reduction Due to SQC, there is increase in efficiency and reduction in cost is easily possible.
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5. Better customer relation The good customer relations can be maintained by the proper use of SQC. Advantage /Benefits of SQC 1. Efficiency and cost reductions 2. Easy detection of fault. 3. Easy application 4. Reduction of scrap. 5. Reduction in consumer complaints. 6. Reduction of men and machine hours. Q.3. Distinguish between Variables and Attributes Solution:No 1 Variables Attributes When the measurement is carried out to When a record shows only the number of find the quality characteristics of articles confirm and non confirming to attribute data It is recorded with the help of laid down components, the quality is said to be any special requirement it is said to be 2 3 4 Ex: expressed in varbles. It is done with the help of precision
measurement. standard. Data obtained is called the continuous Data obtained is called discrete data data. The value cannot be fractions Dimension of a parts measured Weight in kg The value cannot be fractions No of defects found in sample Cracks in sheet by spot weld.
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Q.4. What is Variation/Variability? What are possible causes of variation? Solution: VARIATION/VARIABILITY
No production process can produce all items exactly alike. Production process consists of combination of men, materials and machine. Each of these elements of combination has some inherent or natural variability, the causes of which cannot be isolated.
Reason for variation 1) Poor raw material 2) Machine vibration 3) Tool wear 4) Improper work setting 5) Faulty work holding device Two types of Variation 1) Chance variation /random variation 2) Assignable variation
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Q.5. Differentiate between the Chance causes and Assignable causes? Solution:No 1 2 3 4 Chance cause This cause occurs by chance. There is a minute amount of variations. They are difficult to trace and un economical to eliminate. With the random variation ,the process is stable to use the 5. sampling procedure These causes flows the statistical laws of variation. 6 Example a. vibration in machine b. variation in material Example a) Faulty set up b) Fault jigs and fixtures Assignable causes This cause occurs due to individual error. There is a small and large amount of variations. They are easy to trace/detect and un economical to eliminate. With the assignable variation ,the process is not stable to use the sampling procedure These causes do not follows any statistical laws of variations.
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Q.6:-Define Solution : -
frequency
distribution.
Describe
various
ways
of
graphical
representation of frequency distribution.
FREQUENCY DISTRIBUTION: 1. When the measured sizes of all the products are plotted against the frequency of occurrences of each size in the form of graph, it is known as frequency distribution. 2. The height of curve at any point is proportional to the frequency of occurrence of that particular size. APPLICATION OF FREQUENCY DISTRIBUTION 1. For producing entire lot character from sample. 2. For determining process capabilities. 3. For comparing inspection results for two machines 4. For analysis effective of tool wear. GRAPHICAL REPRESENTATION OF FREQUENCY DISTRIBUTION 1. Frequency Histogram 2. Bar chart 3. Frequency Polygon 4. Cumulative Frequency Distribution
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Frequency distribution can be represented graphically by following ways. Frequency Histogram: 1) In the graph the sides of column represents the upper & lower cell boundaries & heights are proportional to the frequencies of occurrences within the cells. 2) In drawing a histogram, It is assumed that the frequency is centered at the mid value of cell or class.
3) Simplicity of construction & inspection of histogram makes it an effective tool.
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4) A random sample is taken from the lot under consideration & measurements
are made for selected quality characteristic. 5) When there is a large amount of highly variable data, then it may be grouped into cell. 6) As a general rule, at least 50 measurements are taken to provide sufficient data to plot the histogram.
1. Bar Chart: 1) Bar chart is a graphical representation of the frequency distribution, in which the bars are centered at the midpoint of the cells. 2) The heights of bars are proportional to the frequencies in the respective cells.
Frequency Polygon: 1) Frequency Polygon is a graphical representation of frequency distribution in which series of lines joining the points are platted at cell midpoints at the height shown for frequency. 2) It consists of a series of straight line joining points which are plotted at all mid points with a height proportional to the frequency. 3) The advantage of frequency polygon is that frequency polygon of several distributions may be plot on the same axis, those by making certain comparisons possible.
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2. OGIVE CURVE 1) Ogive curve are used to plot cumulative frequencies of value less than or greater than respective cell bounded. 2) Less than Ogive: Upper class boundary and less than cumulative frequency. 3) More than Ogive : Lower class boundary and more than cumulative frequency
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Q.7: - Define 1. Grouped Frequency 2. Relative Frequency 3. Cell 4. Universe. Solution: -
1) Cell : While grouping the data into a frequency distribution, the cell boundaries should be chosen half way between two possible observations and cell intervals should be equal. The interval along the scale of measurement of each ordered class is termed cell.
2) Grouped frequency : It is an arrangement, which shows the frequency of occurrence of values in ordered classes.
3) Relative frequency: The relative frequency of any cell is the frequency for that cell divided by total numbers of observations.
4) Unit: -
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Unit is one of a number of similar items, objects etc.
5) Universe or population: The universe may be thought of as a common source, from which the total collection of unit is obtained. Statistical methods are based on the concept of a distribution of exceeding larger number of observations, termed as Infinite Universe or Population. . Q.8: -Define central tendency OR Define 1. Mean 2. Median 3. Mode 4. Range Solution: Central Tendency: When accurately measured, the dimensions of most of the components tend to concentrate close to middle of the two extremes. This is called as Central Tendency.
1. Arithmetic Mean: -
The arithmetic mean is the average of all the values of the variable in the sample. If X1,X2,X3,.,Xn are the n values of the variables X in the sample, then their arithmetic mean is given by,
X1 + X2 + X3 +.................+ Xn n
X=
i.e. X = 2. Median:
When all the observations are arranged in ascending or descending order, then the median is the magnitude of middle case.
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Case 1:If n is odd, the observations are arranged in ascending order, then median is given by, ( Case 2:If n is even, then the median is taken as, Average of ( ) value.
n 2
th
n +1 th ) 2
value.
value or ( + 1 )
n 2
th
3. Mode: Mode is the value that occurs most frequently in a frequency histogram or frequency polygon. It is the observed value corresponding to the high point of the graph. For Example, The recorded observations are, 2,3,2,4,5,2,7,6,2,4,2 Here, 2 occurs most frequently, hence mode = 2
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Q.9 :- Define dispersion. How will you measure dispersion? Solution:DISPERSION: The extent to which data is scattered about the zone of central tendency is known as dispersion. Common measure of Dispersion 1. Range 2. Standard deviation 3. Variance The various measures of dispersion are, 1) Range (R): Range is the difference between largest observed value & smallest observed value. It is the simplest measure of dispersion in a sample. It is particularly used in the control chart. Range = largest observed value smallest observed value.
2) Standard Deviation: - (RMS value)

Standard Deviation is defined as the root mean square of the deviations from the arithmetic mean. If X1, X2, X3 Xn are n number of observations, Then, X = arithmetic mean,
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X X ) + ( X X ) +..........( X X ) = ( n
1
3) Variance: It is the sum of squares of deviations from the arithmetic mean divided by number of observations. In other words, Variance is the square of standard deviation i.e. 2.
Q.10: - What is N.D. curve. Give characteristics & applications of N.D. Curve. Solution:Normal Distribution Curve In the frequency distribution, if the number of observations is increased and if only the chance causes of variation are present in the quality characteristics measured, the frequency polygon assumes a bell-shape and approximates to normal distribution curve.
Characteristics 1. Normal distribution curve is bell shaped & symmetrical about the mean.
2. The curve is fully defined by X & .
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3. Theoretically N.D. curve extends from -3 to +3. However for all practical
purposes, we can consider normal curve extending only 3 values to the left and 3 values to right of mean. I.e. X 3 .
4. The most coated limits in connection with the curve are as follows
Specification Limits X X 2 X 3 Percent Of Total Area 68.26% 95.46% 99.73%
When we select 3 limits, we are 99.73% sure that the observations will lie within these limits.
Applications of N.D.curve: 1. The frequency of occurrence of the parts are plotted against their respective
classes are sizes. If the curve is approximates to N.D. Curves, it means no assignable causes of variation are present i.e. chance causes are present. 2. It is useful in process capability study to find whether the process is capable of meeting the specified tolerance or not. 3. The area under the curve between two limits represents the total percents of production that will fall either these limits. Q.11: - Define Control Chart. State its purposes?What are its objectives? Solution: -
Control Chart: 1) It is a graphical representation of the collected information. 2) The information may pertain to measure quality characteristic (e.g. length, diameter, thickness etc.). 3) Control chart is a device for specifying state of statistical control & for attaining quality control. 4) It is a tool to judge whether a state of statistical control has attended.
Purpose of Control Chart: 1) To find out the changes in the quality of product; so that rectification can be equally made to correct the process before large quantity of defectives (or
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scrap) are produced. i.e. the chart gives warning of change in trend of production towards the increasing number of defective articles. 2) To determine whether the given process can meet the existing specification without a fundamental change in production process. 3) To secure information to be used in establishing or changing production procedure. 4) To give a feedback of information, which can be used for planning & control purposes. 5) To ensure product quality level.
Objectives of different control charts:The commonly used control charts are,
1. X Chart: - It shows variation in average of variation of samples i.e. it shows

centering of process
2. R Chart: - It shows uniformity or consistency of process i.e. it shows

variations ranges of samples.
3. Charts: - It shows variation of the process.
X & R or X & Charts are used in combination to control the process.

TYPES OF CONTROL CHARTS:-
CONTROL CHART
X- R chart (For measurable quality characteristics available)
1) P chart & 2) C chart (For attribute data)

26 Vaibhav Vithoba Naik
Q.12: -Describe the method of constructing X & R charts & explain how these charts help in determining lack of controls. Solution: Step I Calculate the average X & range for each sample: A good number of samples of items manufactured are collected randomly at different intervals of time & their quality characteristics (e.g. diameter, thickness, wt., etc.) are measured. For Examples: If a sample contains five items, whose dimensions are X1, X2, X3, X4 & X5, then
X= X1 + X2 + X3 + X4 + X5 5
& R = largest value smallest value. Step II Calculate grand average X & average range R . It is obtained by dividing the sum of X value by number of samples i.e. subgroups,
i.e. X =
X , Where N= Number of samples, and R = R

N
N
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Step III Calculation of 3 limits for X chart, The control limits are given by, Upper control limit X = UCL X = X + 3 . X Lower control limit X = LCL X = X - 3 . X Step-IV Calculation of 3 limits for R chart, UCL R = D4 R UCL R = D3 R where the values of various factors A, A1, A2, D1, D2, D3, D4 are based on normal distribution & can be found from standard tables for a particular sample size. Step V Plot X & R chart: For X chart, the central line on X chart should be drawn as solid horizontal line as X . The upper & lower control limits should be drawn as dotted horizontal lines at the calculated value. For R chart, central line will be indicates R & control limits are shown by dotted horizontal lines. Step VI Plot the average of samples in X chart in the order collected & points outside the control limits are indicated by cross. Plot the ranges in R chart & points outside the control limits are indicated by circles. Step VII Interpretation/preliminary conclusions from the control charts. The lack of control is indicated by points falling outside control limits on either X & R chart. When all the points fall inside, it means the process is in control. 1 out of 35 or 2 out of 100 points can be tolerated & process is said to be in control.
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Q.13: -Differentiate between a defect & defective. Solution: A. Defective: 1. An item is said to be defective if it fails to conform to the specifications in any of the quality characteristics. B. Defect: -
1. Each characteristic that does not meet with the specifications is called as defect.
2. An item is said to be defective if it contains at least one defect. 3. For e.g. if a casting contains undesirable hard spots, blowholes, cracks etc., the casting is defective and hard spots, blowholes, cracks are called as defects. Q.14: Define Fraction Defective. How will you draw P chart? Solution: FRACTION DEFECTIVE: It is defined as the ratio of number of defective articles to the total number of articles actually inspected. It is always expressed as decimal fraction. P- Chart It is an attribute control chart i.e. for quality characteristics that can be classified as either conforming or non-conforming to the specifications. For e.g. dimensions checked by GO & NO - GO gauges.
Step to draw P Chart: 1) Record the data for each subgroup on no. of articles inspected and no. of defectives 2) Compute P (fraction defective) for each subgroup
P=
No. Of defectives in subgroup No. of articles inspected in subgroup
3) Compute P =average fraction defective
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P=
Total No. Of defectives in a period Total No. of articles inspected in a period
4) Compute Control limits
UCLP = P + LCLP = P
P + (1 P) n P + (1 P) n
5) Plot each point as obtained, plot control limits as calculated. The points falling outside control limits are identified, (If any). 6) If the points fall outside the control limits, there may be two reasons. a) Assignable causes of variation may be present. b) Quality level is different for assumed standard P. . Q15.: -Short Note on P- Chart? Solution: P- Chart It is an attribute control chart i.e. for quality characteristics that can be classified as either conforming or non-conforming to the specifications. For e.g. dimensions checked by GO & NO - GO gauges.
Step to draw P Chart: 7) Record the data for each subgroup on no. of articles inspected and no. of defectives 8) Compute P (fraction defective) for each subgroup
P=
No. Of defectives in subgroup No. of articles inspected in subgroup
9) Compute P =average fraction defective P= Total No. Of defectives in a period Total No. of articles inspected in a period
10) Compute Control limits
UCLP = P +
P + (1 P) n
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LCLP = P
P + (1 P) n
11) Plot each point as obtained, plot control limits as calculated. The points falling outside control limits are identified, (If any). 12) If the points fall outside the control limits, there may be two reasons. c) Assignable causes of variation may be present. d) Quality level is different for assumed standard P.
Q.16: - What is the purpose of P-Chart? Solution Purpose of P-Chart Because of lower inspection & maintenance costs of p-chart, they usually have a greater area of economical applications than control charts for variable. 1. To discover avg. proportion of defective articles submitted for inspection, over a period of time. 2. In a sampling inspection of large lots. 3. To bring attention to management, any changes in average quality level. 4. To discovers identity & correct causes of bad quality. 5. Provides management with useful record of quality history.
6. To suggest where it is necessary to use X & R chart to diagnose quality problems.

Q.17: -Short Note on C chart Solution: -
C Chart (Control Chart for defects per unit ): 1. It is also another type of control chart for attribute.
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2. It this chart, sample size remains constant. It finds no of defects per unit of production. Example of this includes Cloth manufacturing & Tube manufacturing. 3. It applies to number ff defects in a subgroup of constant size. Central line = C =
No. of defects in all subgroups No. of defects in all subgroups
Upper control limit UCL C = C + 3 C Lower control limit LCL C = C 3 C 4. Plot each point as obtained, plot control limits as calculated. 5. The points falling outside control limits are identified Applications of C chart. 1. Number of surface defect in aircraft wing. 2. Number of surface defect in galvanized sheet. 3. Number of small holes in glass bottles. 4. Number of defect such as blowholes, cracks in a casting. 5. Number of imperfections observed in a cloth of unit area. Q.18: -Differentiate between Variable & Attribute Chart OR Differentiate between X & R chart with C, P chart.
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Variable Charts Examples: - X & R Data required is variable data (i.e. measured quality characteristic) Field of Application: Control of
Attribute Charts Examples: - P, np, C, U charts. Data required is attribute
data
(i.e.
conformance or non-conformance using laid down standard GO & NO gauges). Field of application: - Control of proportion of defectives or defect in a sample of constant size or number of defects per unit. of Data required are often already available
individual quality characteristic. Provides maximum utilization
information available from data. form inspection records. Provides detailed information on process They do not provide detailed information for average & variation for control of control of individual dimension. They are more simple as compared to X, R charts, so can be easily understand They involve less cost & time. Sample size is generally larger. individual dimension. They are not easily understood unless training is provided. They involve more time for measuring, calculation & plotting. Sample size is small.
Q.19: - What is Process capability? Explain its role in achieving the Quality? OR How Process capability is useful in industry? Solution: PROCESS CAPABILITY It may be defined as the minimum spread of specific measurement variation, which will include 99.73% of the measurement from the given processes as shown by limits in the N-D curve. In other words, Process capability = 6, since 6 is taken as a measure of spread of process, which is also called natural tolerance.
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By this study, it becomes possible to know the % of products, which will be produced within 3 limits on either side of mean X .
ROLE OF PROCESS CAPABILITY IN ACHIEVING QUALITY

1. The capacity of the process and available equipment can be utilized effectively and efficiently. 2. The job with tight tolerance can be assigned to the capable machines. 3. The tools designer can find out the places where tooling improvement can be done to maintain the process capability. 4. The capability study helps in maintenance schedule. 5. The machine settler can judge the efficiently of the machine. 6. The machine operators can take decision selecting the machines. USE OF PROCESS CAPABILITY STUDY 1. It determines the ability of the process meet standard and specifications. 2. It can be used to establish the new standard. 3. It measures the variability of the process. 4. It determines the causes of the inherent and actual variability.
Applications of Process Capability study:1. To find whether the process is capable of meeting the specified tolerance limits. 2. Discover why the process capable is failing to meet the specifications. 3. The knowledge of process capability studies lead to improve equipment maintenance, improved operator training & reduce costs. Q.20: - Explain the steps involved in process capability? Give its applications. Solution: Procedure for doing Process Capability study Step 1. Calculate X and R for each sample. Step 2. Calculate Grand average X & average range R , this measures centering of process.
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Step 3. Calculate process capability = 6 = 6
R R 6x d2 d2
where d2 is a factor for particular sample size.
This measures the piece-to-piece variability of process. Step 4. Calculate specified tolerance.i.e. (Xmax Xmin). When a controlled process must meet two specification limits on individual values, upper & lower specification limits, the possible situations may be grouped into 3 general classes as described below.
1. When (Xmax Xmin) > 6

Where Xmax = Upper specification limit Xmin = Lower specification limit i.e. specified tolerance > natural tolerance Conclusions 1) With any position a,b or c practically all the products manufactured will meet the specifications
2) If (Xmax Xmin/6) ratio is considerably large, frequency of control chart may be

reduced.
2. When (Xmax Xmin) < 6 i.e. specified tolerance is < natural tolerance
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Conclusion In this type of situation defectives will always be there. Remedy:a. Increase the tolerance.
b. Reduce the dispersion.

c. Suffer and sort out the defectives if it economical to make the fundamental changes in process.
3. When (Xmax Xmin) = 6

Conclusion Spread of process is approximately equal to difference between upper & lower specification limits.
Remedy :a. It is necessary to maintain the centering of process. b. Reduce dispersion if it is economical. c. Advisable to increase tolerance. Q.21: -What do you mean by Acceptance sampling? How does it help in Quality Control? Solution: ACCEPTANCE SAMPLING 1) Acceptance sampling is the process of evaluating a portion of the products in lot for the purpose of accepting or rejecting the lot on the basis of number of defective parts found in a random sample drawn from the lot. 2) If the number of defective items does not exceed the predefined level, the lot is accepted otherwise rejected.
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NEED OF ACCEPTANCE SAMPLING 1. To interprete the specification. 2. To measure the product. 3. To compare the specification and the product. 4. To provide the basis for constructing the sampling plans. TWO METHODS OF ACCEPTANCE SAMPLING /SAMPLING INSPECTION Inspection for acceptance purpose is carried out at many stages in manufacturing. There are generally two ways in which inspection is carried out. 1. 2. 100% inspection. Sampling inspection.
A. 100% inspection 1) In 100% inspection, all the parts or products are subjected to inspection, where as in sampling inspection only a sample is drawn from the lot & inspected. B. Sampling inspection. 1) In sampling inspection, certain samples are selected from a lot and they are checked. 2) Decisions are made after inspecting the samples selected.
Q.22: - Give the advantages and limitations of ACCEPTANCE SAMPLING? Solution: ADVANTAGES OF ACCEPTANCE SAMPLING 1. Cost and time required is less compared to 100% inspection. 2. Less manpower is required for the inspection 3. It takes less time and hence delivery time and hence delivery commitments can be easily met. 4. The error and fatigue observed in 100% inspection is not there. 5. The quality awareness is increases in the business organizations.
37 Vaibhav Vithoba Naik
DISADVANTAGES OF ACCEPTANCE SAMPLING 1. Proper selection of sampling plans, sampling size, proper acceptance and rejections number is important while doing. 2. There are risk of accepting bad lots and rejecting good lots. 3. The field of application is limited depending on the product. 4. The sampling provides less information than the 100% inspection.
Q.23: - Give the advantages and limitations of sampling inspection over 100% inspections. Solution: ADVANTAGES AND LIMITATIONS OF SAMPLING INSPECTION OVER 100% INSPECTIONS.
Advantages of Acceptance sampling: The advantages of sampling inspection over 100% inspections: 1) Cost & time read is quite less than 100% inspection.
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2) Problems of inspection fatigue are eliminated. 3) Less damage to products because only few items are subjected to handling during inspection 4) The inspector error introduced by 100% error is minimized. 5) The lot is disposed off in shorter period, so that scheduling & dispatch dates are improved. 6) It exerts more effective pressure on quality improvement. Limitations of Acceptance sampling: 1) Since only a part is inspected, the sample may not represent the exact picture of the entire lot; hence there is likelihood of risk of making wrong decisions about the lot. 2) The producer will pass on the cost of rejected loss on the consumer. 3) This method may not be suitable for tasking decision on acceptance or rejection of very costly items. 4) It is necessary to use random sampling, select proper sample size & acceptance criteria for accurate results. Q.24: -State the factors on which success of sampling inspection depend? Solution: - Factors on which success of sampling inspection depends are :a) Random sampling. b) Proper sample size & lot size. c) Acceptance criteria. d) Quality characteristic to be measured.
Q.25: - What is O.C. Curve? Sketch neatly actual O.C. curve?State its parameter? Solution: O.C. Curve (Operating Characteristic Curve) 1. The operating characteristic curve for an attribute-sampling plan is a graph of fraction defectives in a lot against the probability of acceptance.
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OR The operating characteristic curve for an attribute-sampling plan is a graph of probability of acceptance versus percentage defectives.
2. The percentage defectives are taken on X axis and the probability of acceptances is taken on Y axis on the graph. 3. It provides both the produces and consumer a graph showing risks each of them takes in term of good product being rejected and bad product is accepted. 4. The shape of O.C. curve depends upon following parameters. N = Lot size from which samples are drawn n = Sample size c = Acceptance number
5. An O.C. curve can be divided into three regions. a. Acceptance quality region. b. Indifference quality region c. Objectionable quality region. Parameter of an OC curve 1. Producers risks 2. Consumers risks 3. Acceptable quality level.
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4. Lot tolerance percentage defective. 5. Average outgoing quality. 6. Average outgoing quality level Q.26: - State the characteristic of an O. C. Curve. Solution: -
Characteristic of O.C.curve: 1) The O.C. curve of an acceptance-sampling plan shows the ability of plan to distinguish between good lots & bad lots. 2) Sampling acceptance plans with same % samples gives very different quality protection 3) For different values of n, N & c, the O.C. curve will differ.
4) But for fixed value of c & n1 the O.C. curve for different values of N are not
appreciable different i.e. it is the absolute size of sample i.e. important than its relative size compared to size of lot.
5) With fixed value N and c < n1 than if n value is larger, better will be
discrimination between good lots & bad lots. 6) With fixed value of C and n < N, than if n is larger, the slope of O.C. curve will be steeper. Q.27: - List the significance of an O. C. Curve. Solution: Significance of an O. C. Curve 1. It compares the performance over a range of possible quality level of submitted product. 2. It provides the means of evaluating the means of evaluating the sampling. 3. It depicts the varying conditions of incoming material. 4. It explains the risk inherent in sampling plan at each level of product quality. Q.28:- Explain the following terms. A. Producers risk B. Consumers risk C. Acceptance Quality Level (AQL) D. Lot tolerance percent defective (LTPD)
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E. Average outgoing quality (AOQ) F. Average outgoing quality level (AOQL) Solution: -
A. Producers risk: 1) The producers risk is the probability of rejecting a good for which otherwise would have been selected (accepted). 2) If the quality is good still from the sampling plan some lots are rejected, then it becomes the risk of producer and producer has to suffer. 3) Producer should not be affected by rejecting a good lot. 4) So producers should be protected against the rejection of relatively better products. 5) The producers can decrease risk by producing product at better quality level than specified AQL depending upon other economical conditions.
B. Consumers risk 1) Consumers risk is defined as the probability of accepting the defective lots which otherwise would have been rejected.
2) If the quality of the product is bad and still some lots are accepted then it becomes
the risk of consumers. 3) If the quality is bad still from the sampling plan, some lots are accepted, the consumers has to suffer. 4) Saying that Pa 0.1 = 2.5 means that the consumer dose not want a worse quality containing more than 2.5% defectives & he would at the most accept 10% of lots containing 2.5% defectives.
C. Acceptable Quality level (AQL): 1) It represents the max proportion of defectives, which the consumer finds definitely acceptable. 2) AQL can also be defined as maximum percent defectives that for the purpose of sampling inspection can be considered satisfactory as a process average.
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3) As an AQL, is an acceptable quality level, the probability of acceptance for an AQL should be high. 4) In fact the producers safe point is termed as AQL
D. Lot Tolerance Percent Defective (LTPD): Lot tolerance percent defective. 1) It can be called as RQL i.e. Rejectionable Quality Level. 2) It is a definition of unsatisfactory quality.
3) It represents the proportion of defectives which consumer finds definitely

unacceptable. 4) As RQL is unacceptable quality level, the probability of acceptance is very low. 5) In fact, the probability of accepting a lot at LTPD represents consumers risk.
E. IQL: - (Indifference quality level)

1) This is a quality level somewhat between AQL & LTPD 2) It is defined as quality level having probability of acceptance of 0.5 for a given sampling plan. F. Average Outgoing Quality (AOQ): 1) An average outgoing quality of a product is important to the customer.
2) The AOQ is the expected average quality going to a customer for the
specified incoming quality level. 3) It represents the average % defective in the outgoing products after inspection, including all accepted & all rejected lots, which have been100% inspected & defectives replaced by non-defectives. 4) So for a given fraction defectives, the lot accepted as a result of first sampling inspection will have a fraction defectives p the rejected lots are subjected to 100% inspection & rectification (defective particles are either replaced or corrected), therefore AQL will be less than p. G. Average Outgoing Quality Level (AOQL): 1) Average outgoing quality level is the maximum average percent defective in the outgoing product.
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2) For any sample size & acceptance number, there is a max. value of AOQ beyond which the average fraction defectives passed forward will not rise, no matter how bad the quality of lots when they arrive at inspection. 3) Because, when incoming quality is good, AOQ must be good. 4) However, when incoming quality is bad, the sampling plan will causes all the lots to be rejected, 100% inspected & rectified. Therefore the outgoing quality will be good. 5) Therefore at either extreme incoming quality very good or very bad, the outgoing quality will tend to be very good. 6) Between these two lots, there will be a point at which the percent of defectives will reach its maximum. This point is known as average outgoing level (AOQL)
Q.29:-Explain Acceptance / Rejection scheme & Acceptance /Rectification scheme? Solution: -
Acceptance / Rejection scheme: 1) The lots are subjected to sampling inspection. 2) If the lot contains more than c defectives it is rejected otherwise it is accepted. 3) The AOQ will be equal to or more than the given fraction defectives. 4) O.C. curve is used to discriminate between good & bad lots.
Acceptance /Rectification scheme :1) The lots are subjected to sampling inspection & of it contains defectives less than c than it is accepted. 2) It the lot contain more than c defectives, it is subjected to 100% inspection & defectives articles are either replaced or corrected before it is passed forward if for a given fraction defectives, the lot accepted as a result of first sampling plan will have fraction defected p, the rejected lots are subjected to 100% inspection & defective articles are replaced or corrected, If AQC will be less than p.
Q.30: -What do you mean by Random Sampling?
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Solution: Random Sampling: -
1) Selecting a sample in such a way that each item in a lot has an equal chance of
being selected is called as Random Sampling. 2) Since a judgment about the lot is to be made on the basis of only a sample it is very important that the sample truly represents the universe (lot) from which it is drawn. 3) Therefore samples must be selected from all sides & different depths of container containing the lot of parts. 4) Also the sample size should be large enough.
Q.30: -State & explain the different sampling plans with respect to their acceptance criteria. Solution: -
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Sampling plans may be grouped into three categories.
A. Single sampling plan: 1) When a decision rejection or acceptance of lot is made on the basis of only one sample, the acceptance plan is known as single sampling plan. 2) In this sampling plan, the decision to accept or reject of a lot is based on the inspection of single sample. 3) It the number of defective found is less than equal to the acceptance number, then the lot is accepted. 4) It the number of defective found is greater than equal to the acceptance number, then the lot or batch is rejected. 5) In this, there are three parameters. N = Lot sizes, n = sample size & C = acceptance number = Maximum number of allowable defectives.
Inspect A Sample Of n Pieces
If number of defectives
Does not exceed C
Exceed C
Accept the lot
Reject the lot
B. Double sampling plan: 1) When the decision is made on acceptance or rejection of the lots on the basis on two samples combined it is called as double sampling plan.
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2) A lot may be accepted at once if the first sample is good enough and rejected at once if sample is bad enough. 3) If the first sample is neither good enough nor bad enough, the decision is based on the evidence of first & second sample combined. 4) Parameters: Let n1 = number of pieces in the first sample C1 = acceptance number for the first sample= max. number of defectives that will permit the acceptance of lot on the basis of first sample. n2 = number of pieces in the second sample. n1+n2 = number of pieces in the two samples combined. C2 = Acceptance number for the two samples combined = max number of defectives that will permit the acceptance of the lot on the basis of first & second sample combined. Inspect a sample of n1 pieces
If number of defectives
Does not exceed C1
C1 < def < C2
Exceed C2
Accept the lot
Reject the lot Take second sample of n2 pieces
If number of defectives in the first & second sample combined
Dose not exceed C2

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Exceed C2
Accept the lot
Reject the lot
C. Multiple sampling plans: 1) The multiple sampling is used when three or more samples of stated size are permitted. 2) The multiple sampling procedures can be represented on a table such as the following. Sample Number First Second Third Fourth Fifth Sample Size n1 n2 n3 n4 n5 Combined samples Size Acceptance n1 n1+n2 n1+n2+n3 n1+n2+n3+n4 n1+n2+n3+n4+n5 c1 c2 c3 c4 c5
Rejection r1 r2 r3 r4 C5+1
3) A first sample of n1 is drawn, the lot is accepted if there are defectives less than c 1
& rejected if there are defectives more than r1
4) Otherwise if c1 < def < r1, a second sample of n2 is drawn, the lot is accepted if
there are defectives less than c2 in combined sample of n1+n2 whereas lot is rejected if there are defectives more than r2. 5) The procedure is continued in accordance with the above table.
6) If by the end of fourth sample, the lot is neither accepted nor rejected, a sample n5
is drawn.
7) The lot is accepted if the number of defectives in the combined sample of n1, n2, n3,
n4, n5 less than c5 & rejected if more than c5+1.
Q.31. Compare the three sampling plans. Solution: Single Sampling plan Generally largest Double sampling plan In between single & Multiple sampling plan Lowest
Number 1.
Feature Avg. number of
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pieces inspected per lot Acceptability to producer Cost of Administration Information available about prevailing quality level Poor, it given only one chance of passing the lot. Lowest
multiple Less acceptable if Most acceptable (Gives IInd chance) In between single & multiple indecision is continued for a larger period Largest
2.
3.
4.
Largest
In between
Lowest
Q.32. What is the Product Reliability ? Solution: PRODUCT RELIABILITY 1) The reliability of a system or device is the probability that it will give satisfactory performance for a specified period of time under specified operating condition. 2) It is expressed as a mathematics probability.
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Parameter involved in the product reliability 1) The equipment and the performance required of it. 2) The conditions under which it is to operate. 3) The time interval/duration of operations. Cause or Failure / Unreliability 1) Design weakness 2) Manufacturing defects. 3) Misuse failure. 4) Environment stresses coming from temperature, humidity, atmospheric pressure, chemical content, radiation etc. 5) Operating stress coming due to voltage, current and frequency.
Q.32. What is the Reliability? What are the factors to be considers while designing a reliable product? Solution: Reliability Reliability can be defines as the degree of assurance or ability of the part to be function under specified conditions for specified time.
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FACTOR TO BE CONSIDERED WHILE DESIGNING RELIABILITY. The factors to be considered while designing reliability are 1. Simplicity of product : Less the number of produt,the more is reliability. 2. Derating Derating means providing safety margin. 3. Redundancy Redundancy means providing stand by component in event of failure of primary item. 4. Safe operation The part fails should not be sudden and damage should be less. 5. Parts should be protected from extreme temperature, pressure and vibrations etc. 6. The product should be easily maintainable and serviceable.
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Q.33. Explain the term MTBF? Solution: Mean time between failure (MTBF) 1) MTBF is defined as the total measured operating time of a population of equipment divided by total number of failures, coupled with an assumption of an exponential distribution of intervals between the failure. 2) It is reciprocal of failure rate .
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=failure rate is number of failure occurring per unit time.
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TOTAL QUALITY MANAGEMENT TQM

Q.1: -Short notes on TOTAL QUALITY MANAGEMENT (TQM)? Solution: TOTAL QUALITY MANAGEMENT (TQM)
1. TQM is defines as control of all the transformation of an organization to satisfy

the customers needs in the most economical ways. 2. It is the way of managing to improve the effectiveness, flexibility and competitiveness of a business as whole. 3. It refers to total involvement of staff in an organization in bringing about quality satisfactions. 4. It is responsible for quality revolution in the industry. 5. Its function is to improve the quality of work of all the people at all functional areas of organization. 6. TQM uses a. Fundamental ideas of group activity. b. Participation of all the statistical and quality tools. c. Self development and creativity. ACTIVITY INVOLVED IN TQM 1) Team work. 2) Integration and co-ordination of all the activities of all department to attain the desired goals. 3) Satisfy the worker emotions. 4) Installing motivation system. 5) Maintain a sound quality system to perform the task. OBJECTIVES OF TQM TQM gives emphasis on 1. Training in problem diagnosis and solution. 2. The effective communication amongst all the department. 3. Developing all the essential and appropriate procedure. 4. Positive attitude of all the employees working in organization so that customer will get the quality product
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Q.2: -Briefly explain the procedure for TOTAL QUALITY MANAGEMENT (TQM) implementations? Solution: TQM IMPLEMENTATION We Deming explained PDCA cycle for implementation of the TQM in any organization
1. PLAN a. Lay down and plan all the policies and objectives of TQM. b. Plan method to achieve the objective of organization. 2. DO a. Provide educational and training to workers and managers to achieve the objectives b. Implementation TQM by introducing the newer things. 3. CHECK a. Check the result by observing them and find cause of the non conformation
b. Analyze the result.

4. ACT a. Try to act for preventing undesired effects. b. Measure the improvements and design for the future.
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Q.2: -Define SQC?Define in short the practical devices used as a tools in statistical control in industry Solution: -
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Explain the different quality standard in brief? Discuss the ISO QUALITY standard .state its at least of 10 clauses? Define quality standard.Disccuss the various quality standard in details with its causes?10m What do you mean by quality standard 5m
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2011-2012

Statistical Quality Control

Mr.VAIBHAV VITHOBA NAIK MECHANICAL ENGINEERING S.S JONDHALE COLLEGE OF ENGINEERING

Industrial Engineering & Enterprise Resource Planning

Statistical Quality Control

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

a. The standard specification :

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

representation of frequency distribution.

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

3) Simplicity of construction & inspection of histogram makes it an effective tool.

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Q.7: - Define 1. Grouped Frequency 2. Relative Frequency 3. Cell 4. Universe. Solution: -

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Unit is one of a number of similar items, objects etc.

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

2) Standard Deviation: - (RMS value)

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

2. The curve is fully defined by X & .

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Vaibhav Vithoba Naik

Industrial Engineering & Enterprise Resource Planning

Objectives of different control charts:The commonly used control charts are,

1. X Chart: - It shows variation in average of variation of samples i.e. it shows

2. R Chart: - It shows uniformity or consistency of process i.e. it shows

3. Charts: - It shows variation of the process.

X & R or X & Charts are used in combination to control the process.