BITS, PILANI DUBAI

First Semester 2010-2011 IV Year Mechanical ME C443 Quality control, Assurance & Reliability Test 1 Date: 24-10-2010 Weightage: 25% Time: 50 min. Marks: 25 # 1. Answer all the questions 2. Assume suitable data, if required 3. Return the QFD sheet with answer script 4. Copy of Appendix A3 is permitted 1 The failure data related to plastic lever-shaft assembly is given below. Form FMEA table and calculate RPN for the data and write your inference.
Components Plastic Lever Types of failures Plastic lever breaks Wear at hole in lever Loose fit Mis orientation Reasons for failure Overload on lever High unit loading Thermal set of plastic lever Inadequate press fit Effects of failure No drive Excessive free play Lever slides off the serration Improper linkage geometry Severity Very high High High Moderate Frequency 1 in 3 1 in 20 1 in 8 1 in 80 Detection possibility Very high Low Low Moderate

Marks

Shaft

Use the table below for rating.

Score 10 9 8 7 6 5 4 3 2 1 Severity Criteria Occurrence Very High Very High High High Moderate Moderate Moderate Low Low Remote Detection Absolute Uncertainty Very Remote Remote Very Low Low Moderate Moderately High High Very High Almost uncertain Hazardous w/o warning >=1 in 2 Hazardous with warning 1 in 3 Very High High Moderate Low Very Low Minor Very Minor None 1 in 8 1 in 20 1 in 80 1 in 400 1 in 2,000 1 in 15,000 1 in 150,000 < 1 in 500M

2 Public transportation is used by an employee to get to work each day. Samples of times recorded are shown. Times are in minutes. Estimate the essential points for the box plot and comment on the results. (80, 75, 90, 95, 65, 65, 80, 85, 70, 100)

3 Fill the data (related to CAD/CAM books) in the QFD chart, estimate the absolute score & goals for the characteristics and comment on the results.

4 Design specifications call for a target value of 16.0 0.2 OZ for a cool drink. (USL = 16.2 OZ & LSL = 15.8 OZ). Observed process output has now shifted and has a mean of 15.9 OZ and a standard deviation of 0.1 OZ. Calculate the cpk value for the data and determine the %non-conformity. 4

House of Quality (HOQ)

First find the median. The median is the value exactly in the middle of an ordered set of numbers. *

68 is the median
Next, we consider only the values to the left of the median: 18 27 34 52 54 59 61. We now find the median of this set of numbers. Remember, the median is the value exactly in the middle oa an ordered set of numbers. Thus 52 is the median of the scores less than the median of all scores, and therefore is the lower quartile.

52 is the lower quartile

BITS, PILANI DUBAI

First Semester 2010-2011 IV Year Mechanical ME C443 Quality control, Assurance & Reliability Test 1 FMEA Table Solutions

Part

Failure mode Plastic lever breaks Wear at hole in lever

Failure Effect

SEV

Faiure cause Overload on lever

OCC

DET

RPN

Priority

Plastic Lever

No drive

144

Shaft

Loose fit Mis orientation

Excessive free play Lever slides off the serration Improper linkage geometry

High unit loading Thermal set of plastic lever Inadequate press fit

294

336

180

Process capability 16.2 15.9 15.9 15.8 Cpk = min 3(.1) , 3(.1) .1 Cpk = = .33 .3 Cpk is less than 1. The process is not capable. Amount of rejection will be Level of sigma, 16.2 15.9 = 3 (0.0013) (.1)

15.8 15.9 = -1 (0.1587) (.1) Total non-conformance = (0.0013+0.1587) = 0.16 = 16%

Median (2nd quartile) = 80 first quartile = 70 third quartile = 90 minimum = 65 maximum = 100 1.5 IQR = 30 1.5 IQR distance = 40 & 120

No point is away from 1.5 IQR-outlier.