QUALITY CONTROL

SESSION 1: PRACTICE EXERCISES

1. A hard-bake process is used in conjunction with photolithography in

semiconductor manufacturing, We wish to establish statistical control of the
flow width of the resist in this process using and R charts. Twenty-five
samples, each of size five wafers, have been taken when we think the
process is in control. The interval of time between samples or subgroups is
one hour, The flow width measurement data (in x microns) from these
samples are shown below. Construct the x and R control charts for the
process.

Solution:
R bar = 8.1302/25 = 0.32521
UCL = RD4 = 0.32521 • (2.114) = 0.68749
LCL = RD4 = 0.32521 • (0) = 0
X bar = 37.64/25 1.5056
UCL = x-bar + A2R = IS056 + (0.577) • (0.32521) = 1.69325
 LCL x-bar - = 1.5056 + (0.577) • (0.32521) = 1.31795

R and x control charts:

Observation: No point lies outside the UCL and LCL. Conclusion: The process is
statistically in control.
2. Construct the x-bar and s charts of the following reading results for engine
piston rings.
x-bar chart:
x-bar = 1850.028/25 = 74.001
UCL = x-bar + A3s = 74.001 + (1.427) * (0.0094) = 74.014
LCL = x-bar -A3s = 74.001 + (1.427) * (0.0094) = 73.988

s-bar chart:
s-bar = 0.2351/25 = 0.0094
UCL = B4S = (2.089) * (0.0094) = 0.0196
LCL = B3S = (0) * (0.0094) = 0

Conclusion: There is no indication that the process is out of control.

 3. Consider the data below, which is a modification of the piston-ring data. Note
that the sample sizes vary from n = 3 to n = 5. Set up the x and s control
charts.

Solution:
The weighted grand mean and weighted average standard deviation are
computed from as follows:

25

∑ ni x i 5 ( 74.010 ) +3 ( 73.996 ) +…+5 ( 73.998 )

x= i=125 =
5+ 3+⋯+5
∑ ni
i =1
8362.075
¿ =74.001
113

[ ][
25 1

∑ ( ni−1 ) s 2 2

]
i 2 2 2 1
i =1 4 ( 0.0198 ) + 2 ( 0.0046 ) +⋯+4 ( 0.0162 ) 2
s= 25
=
5+ 3−1 …+5−25
∑ ni−25
i=1

[ ]
1
0.009324 2
¿ =0.0103
88

The control limits for the x-bar and c-bar charts are:
x-bar = 74.001
UCL = 74.001 + (1.427) • (0.0103) = 74.016
LCL = 74.001 + (1.427) • (0.0103) = 73.986
s-bar = 0.0103
UCL= (2.089) • (0.0103) = 0.022
LCL = (0) • (0.0103) = 0

4. Frozen orange juice concentrate is packed in 6-oz cardboard cans. These

cans are formed on a machine by spinning them from cardboard stock and
attaching a metal bottom panel. By inspection of a can, we may determine
whether, when filled, it could possibly leak either on the side seam or around
the bottom joint. Such a nonconforming can has an improper seal on either
the side seam or the bottom panel. Set up a control chart to improve the
fraction of nonconforming cans produced by this machine.

Solution:
To establish the control chart. 30 samples of n = 50 cans each were selected
at half-hour intervals over a three-shift period in which the machine was in
continuous operation. Construct a control chart using this preliminary data to
determine if the process was in control when these data were collected.

p-bar = 347 / (30) • (50) = 02313

p ±3
√ p ( 1−p )
n
=0.2313 ±3
√ 0.2313 ( 0.7687 )

¿ 0.2313 ± 3 ( 0.0596 )
50

¿ 0.2313 ± 0.1789

UCL= p+ 3
n√
p (1− p )
=0.2313+0.1780=0.4102

L CL= p−3
n√
p ( 1− p )
=0.2313−0.1780=0. 0524
 Two points, those from samples 15 and 23, plot above the upper control limit,
so the process is not in control. These points must be investigated to see
whether an assignable cause can be determined. If the in-control value of the
fraction nonconforming small, another useful criterion is to choose n large
enough so that the control chart will have a positive lower control limit. This
ensures that we will have a mechanism to force us to investigate one or more
samples that contain an unusually small number of nonconforming items.
Where L is the sigma limns. The minimum sample size (n) needed to give a
positive lower limit control limit is given by the following equations:

LCL=P−L
( 1− p ) 2
n√
p ( 1− p )
>0

n> L
P
For example, if p = 0.05 and three-sigma limits are used. the sample size
must be: Thus, if n ≥ 172 units. the control chart will have a positive lower
control limit.

5. Set up an np control chart for the orange juice concentrate can process in the
previous case.
Solution: p-bar = 02315; n = 50

U CL=n p+3 √ n p ( 1− p )

¿ 50 ( 0.2313 ) +3 √ ( 50 ) ( 0.2313 ) ( 0.7687 )¿ 20.510

 Center line=n p=50 ( 0.2313 )=11.565

L CL=n p−3 √ n p ( 1− p )

¿ 50 ( 0.2313 )−3 √ ( 50 ) ( 0.2313 ) ( 0.7687 )

¿ 2. 620

6. The table below presents the number of nonconformities observed "126

successive of 100 printed circuit boards, Note that, for reasons of
convenience. the inspection unit defined as 100 boards Set up a c chart for
these data.

Since the 26 samples contain 516 total nonconformities. c-bar 516/26 = 19.85
UCL=c+ 3 √ c=19.85+3 √ 19.85=33.22
Center line=c=19.85
L CL=c−3 √ c=19.85−3 √ 19.85=6.48
 The number of observed nonconformities from the preliminary samples is
plotted on this chart. Two points plot outside the control limits, samples 6 and
20. Investigation of sample 6 revealed that a new inspector had examined the
boards in this sample and that he did not recognize several of the types of
nonconformities that could have been present.

Furthermore, the unusually large number of nonconformities in sample 20

resulted from a temperature control problem in the wave soldering machine,
which was subsequently repaired. Therefore, it seems reasonable to exclude
these two samples and revise the trial control limits. The estimate of c is now
computed as: c-bar = 472/24 = 19.67. The revised control chart limits are:
UCL=c+ 3 √ c=19.67+ 3 √ 19. 67=32 . 97
Center line=c=19. 67
L CL=c−3 √ c=19. 67−3 √ 19. 67=6. 36
These become the standard values against which production in the next
period can be compared.

7. A supply chain engineering group monitors shipments of materials through the

company distribution network. Errors on either the delivered material or the
accompanying documentation are tracked on a weekly basis. Fifty randomly
selected shipments are examined, and the errors recorded. Data for twenty
weeks are shown in the table. Setu a u control chart to monitor this process.
Solution: u-bar = 1.48/20 = 0.0740

UCL=c+ 3
√u
n
=0.0740+3
√0.0740
50
Center line=c=1.93
=0.1894

L CL=c−3
Since LCL < 0, set LCL = 0
√u
n
=0.0740−3
√
0.0740
50
=−0.0414