FAKULTI TEKNOLOGI DAN KEJURUTERAAN

INDUSTRI DAN PEMBUATAN

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

QUALITY CONTROL
BMIP 2333 TUTORIAL 3 SESI 2024/2025

ANSWER ALL QUESTIONS

CONTROL CHART FOR VARIABLE

Question 1
The following table gives the average and range in Kg for tensile test on plastic cord. The
subgroup size is 4.
(a) Determine the trial central line and control limits.
(b) If any points are out of control, assume assignable causes , calculate the revised
limits and central limits.

Subgroup No. X R
1 476 32
2 466 24
3 484 32
4 466 26
5 470 24
6 494 24
7 486 28
8 496 23
9 488 24
10 482 26
11 498 25
12 464 24
13 484 24
14 482 22
15 506 23
16 496 23
17 478 25
18 484 24
19 506 23
20 476 25
21 485 29
22 490 25
23 463 22

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 24 469 27
25 474 22

Question 2
Construct the X and R charts for the data on shampoo weight in kilograms below :

Subgroup
No. X1 X2 X3
1 6.01 6.01 5.97
2 5.99 6.03 5.99
3 6 5.96 6
4 6.01 5.99 5.99
5 6.05 6 6
6 6 5.94 5.99
7 6.04 6.02 6.01
8 6.01 5.98 5.99
9 6 6 6.01
10 5.98 5.99 6.03
11 6 5.98 5.96
12 5.98 5.99 5.99
13 5.97 6.01 6
14 6.01 6.03 5.99
15 6 5.98 6.01
Subgroup
No. X1 X2 X3
16 6 5.98 6.02
17 5.97 6.01 5.97
18 6.02 5.99 6.02
19 5.99 5.98 6.01
20 6.01 5.98 5.99
21 5.97 5.95 5.99
22 6.02 6 5.98
23 5.98 5.99 6
24 6.02 6 5.98
25 5.97 5.99 6.02
26 6 6.02 5.99
27 5.99 5.96 6.01
28 5.99 6.02 5.98
29 5.99 5.98 5.96
30 5.97 6.01 5.98

CONTROL CHART FOR ATTRIBUTE

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Question 1
Daily inspection result for the model of electric carving knives are given in the follwoing
table.

(a) Determine the most suitable chart to use.

(b) Calculate the central line and control limit for each subgroup.
(c) Based on the information obtained in (a)and (b), plot the relevant graf.
(d) Assume that any out of control points have assignable causes, determine the
revised central line and control limit . (Remark: Number inspected on 26-Jun is
1535).
(e) Using the control limits for an average subgroup size technique, minimize the effect
of the variable subgroup size. (Remark: Need to include the chart showing the new
obtained control limits).

Date Subgroup No. Number Inspected Number of Nonconforming

29-Mei 1 2365 55
30-Mei 2 1451 18
31-Mei 3 1935 50
1-Jun 4 2450 42
2-Jun 5 1568 39
3-Jun 6 2168 52
4-Jun 7 1941 47
5-Jun 8 1962 34
6-Jun 9 2015 29
7-Jun 10 1238 53
8-Jun 11 2356 45
9-Jun 12 1464 26
10-Jun 13 2061 47
11-Jun 14 2563 34
12-Jun 15 2350 31
13-Jun 16 1456 38
14-Jun 17 1509 28
15-Jun 18 2222 30
16-Jun 19 2678 113
17-Jun 20 2252 58
18-Jun 21 1641 34
19-Jun 22 1782 19
20-Jun 23 1993 30
21-Jun 24 2000 17
22-Jun 25 2365 46

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Question 2

Smartbulbs Inc is a famous LED bulb manufacturer. The supervisor drew a

randomly constant sample size of 200 bulbs every hour and reported the
number of defective bulbs for each lot. Based on the given data, prepare the
control chart for the number of defectives and determine whether the process
is in statistical control.

Lot Number of defective

units found in the sample
1 4
2 8
3 6
4 6
5 4
6 8
7 2
8 1
9 9
10 6
11 8
12 1
13 2
14 9
15 4
16 3
17 9
18 6
19 2
20 7

Question 3
Davis plastics produces plastic baseball bats. These bats are inspected dailty but are not
inspected at a constant number each day. Need the control chart shows how many bats
were inspected and how many nonconformities were found per unit.

(a) Determine the most suitable chart to use.

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 (b) Calculate the centreline and control limits
(c) Based on the information in (a)and (b), plot the relevant graf.
Date Number Inspected Count of Nonconformities
17 126 149
18 84 91
19 96 89
Month of April

20 101 97
21 100 140
24 112 112
25 79 89
26 93 119
27 88 128
28 105 117
1 99 135
2 128 155
3 113 145
Month of May

4 120 143
5 81 94
8 85 104
9 130 157
10 97 121
11 78 83
12 110 120
2025 2388

Question 4

Mobile charger supplier drawn randomly constant sample size of 1 unit charger
every day for quality control test. Defects in each charger are recorded during
testing. Based on the given data, draw the appropriate control chart and
comment on the state of control.

Lot Number of defects found

numbe in the sample
r
1 12
2 14
3 16
4 18
5 16
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 6 14
7 12
8 12
9 32
10 16
11 18
12 16
13 14
14 12
15 16
16 18
17 12
18 19
19 18
20 21

PROCESS CAPABILITY

Question 1
Determine the process capability of silicon wafer thicnkness in micron for the data delow.
Also determine the Cp and Cpk for a USL of 0.9 and an LSL of 0.6.

Subgroup No. X1 X2 X3 X4
1 0.85 0.65 0.65 0.7
2 0.75 0.85 0.75 0.85
3 0.8 0.8 0.75 0.7
4 0.65 0.75 0.6 0.7
5 0.75 0.7 0.65 0.8
6 0.6 0.75 0.75 0.7
7 0.8 0.75 0.65 0.75
8 0.7 0.6 0.75 0.75
9 0.75 0.85 0.85 0.8
10 0.6 0.7 0.6 0.8
11 0.8 0.75 0.9 0.5
12 0.75 0.85 0.85 0.65
13 0.7 0.7 0.75 0.7
14 0.65 0.7 0.85 0.75
15 0.85 0.75 0.8 0.8
16 0.8 0.75 0.75 0.8
17 0.7 0.85 0.75 0.7
18 0.7 0.6 0.7 0.7
19 0.65 0.65 0.85 0.65
20 0.65 0.6 0.6 0.65

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 21 0.55 0.5 0.65 0.8
22 0.75 0.65 0.65 0.8
23 0.8 0.65 0.75 0.65
24 0.65 0.6 0.65 0.6
25 0.65 0.7 0.7 0.6

Question 2
Control chart for X and R are to be established on a certain dimension part, measured in
mm. Data were collected in subgroup sizes of 6 and are given below.
(a) Determine the trial central line and control limits.
(b) Assume assignable causes and revise the central line limits.
(c) What is the process capability .

Subgroup No. X-bar R

1 20.35 0.34
2 20.40 0.36
3 20.36 0.32
4 20.65 0.36
5 20.20 0.36
6 20.40 0.35
7 20.43 0.31
8 20.37 0.34
9 20.48 0.3
10 20.42 0.37
11 20.39 0.29
12 20.38 0.3
13 20.40 0.33
14 20.41 0.36
15 20.45 0.34
16 20.34 0.36
17 20.36 0.37
18 20.42 0.73
19 20.50 0.38
20 20.31 0.35
21 20.39 0.38
22 20.4 0.33
23 20.41 0.32
24 20.4 0.34
25 20.40 0.3

RELIABILITY & MSA

Question 1

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Bunga Raya Sdn. Bhd. preffered to illustrate a gauge repeatability and reproducibility study,
suppose that a gauge used to measure the thickness of a gasket having a specification of
0.50 mm to 1.00 mm is to be evaluated. Ten parts have been selected for measurement by
three operators. Each part is measured twice with the results as shown in Table .

Gasket Thickness Data

Number of operators 3 Upper Specification Limit 1

Number of
trial (r) 2 Lower Specification Limit 0.5

Number
Number of
of operators 3 Upper Specification Limit 2
samples
Number (n)
of trial 2 10 Std Deviation
Lower Specification Limit 0.2
0.5
Number of smples 10 Process Standard Deviation 1.5
Data Operator 1 Operator 2 Operator 3
Trial Trial Trial
Sample# 1 2 Range 1 2 Range 1 2 Range
1 0.630 0.590 0.560 0.560 0.510 0.540
2 1.000 1.000 1.040 0.960 1.040 0.960
3 0.830 0.770 0.800 0.760 0.800 0.760
4 0.860 0.940 0.820 0.780 0.810 0.810
5 0.590 0.510 0.630 0.590 0.460 0.490
6 0.980 0.980 1.000 1.000 1.040 1.000
7 0.960 0.960 0.830 0.770 0.950 0.950
8 0.860 0.830 0.860 0.940 0.810 0.810
9 0.970 0.970 0.980 0.940 1.030 1.030
10 0.640 0.720 0.560 0.520 0.840 0.810
Range average 0.037 0.042 0.025
Sample average

(a) Determine the value for each R1, R2, and R3.
(b) Compute the different mean value of X diff and the overall average range Ŕ .
(c) Calculate the Repeatability, Equipment Variation (EV) and Reproduceability,
Appraisal Variation (AV).
(d) Solve the overall measurement in percentage of Repeatability & Reproduceability
(GR&R) based on the result of EV and AV.
(e) Referring to results of (c) and (d), analyse the condition of related resources.
Question 2
A common household alarm system includes components such as power source, battery,
sensors, CPU, keypad and siren. This sytem is wired to the doors and windows, sounds a

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siren and calls the police. It is arranged in a combination of series, parallel circuitry system.
Figure Q3 presents the alarm system reliability diagram.

Figure Q3: Alarm System Reliability Diagram

(a) Calculate the combined reliability of the power source and the battery.
(b) Calculate the combined reliability of the sensors.
(c) Calculate the combined reliability of the CPU, keypad and siren.
(d) Calculate the combined reliability of the overall alarm system.
(e) Explain why a parallel system reliability is more reliable than a system in series
using the example of the household alarm system.

ADVANCED QUALITY CONTROL

(a) Explain the defination of Design of Experiments (DOE)?

(b) In conducting experiment, explain the Steps in planned experimentation
(c) Researcher are studying the effect of tire pressure, gas types , oil types and vehicle
speed on gas mileage. Problem : For single factor experiment treatment, list the
combination factors may provides the best gas millage ?

Factor Level 1 Level 2

Tire Pressure 28 psi 35 psi
Speed 55 mph 65 mph
Oil 30 kg 40 kg
Gas regular premium

FMEA & QFD

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Question 1
(a) Describe the concept of FMEA
(b) Construct the 5 main steps to conduct a FMEA.

Question 2

(a) Define the meaning of QFD

Appendix :

D2 value for GRR computation

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