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Birla Institute of Technology & Science, Pilani Distance Learning Programmes Division First Semester 2008-2009

Comprehensive Examination (EC-2 Regular)

 Course No. Course Title Nature of Exam Weightage Duration Date of Exam : ET ZC432 : QUALITY CONTROL ASSURANCE & RELIABILITY : Open Book : 60% : 3 Hours : 27/09/2008 No. of Pages = 2 (FN) No. of Questions = 7 Note:

1. Please follow all the Instructions to Candidates given on the cover page of the answer book.

2. All parts of a question should be answered consecutively. Each answer should start from a fresh page.

3. Leave about one inch margin space on all four sides of the answersheet.

4. Mobile phones and computers of any kind should not be used inside the examination hall.

5. No need for any graph sheets. All graphs can be drawn roughly in the answer book itself.

Q.1

Automatic machines that fill packages of all-purpose flour to the desired standard weight need to be closely monitored. A random sample of 4 packages is selected and weighed. The average weight is then computed. Observations from 15 such samples are shown in the following table.

 Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Xbar 80.2 80 79.6 80.3 80.1 80.4 79.5 79.4 79.7 79.5 80.3 80.5 79.8 80.4 80.2

The desired weight of packages is 80 oz. Historical information on the machine reveals that the standard deviation of the weights of the individual packages is 0.2 oz. Assume an acceptable Type I error rate of 0.05. Also assume that it is desired to detect shifts in the process mean of 0.15 oz.

a. Construct and draw a cumulative sum chart and determine whether the machine needs to be adjusted to meet the target weight.

b. Determine the parameters of an appropriate V-mask.

c. Specify the scale factor you use in your cusum plot. [10]

Q.2

Observations are taken from the output of a company making semiconductors. The following table shows the sample size and the number of non-conforming semiconductors for each sample.

 Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Inspected items 80 120 60 150 140 150 160 90 100 160 110 100 200 90 160 Non conforming 3 6 4 5 8 10 7 6 5 12 8 5 14 4 5 items Sample 16 17 18 19 20 21 22 23 24 25 Inspected items 230 200 150 210 190 160 100 100 90 160 Non conforming 3 12 8 6 4 9 8 12 7 10 items

a. Construct and draw a p-chart by setting up the exact control limits for each sample

b. Are any samples out of control? If so, assuming special causes, revise the centre line and control limits

c. Based on the data above, construct a standardized p-chart and discuss your conclusions. [10]

Q.3 A company named HMIL is investigating two potential vendors on the timeliness of their

deliveries. A random sample of size 10 from the first vendor produced an average delay time of 4.5 days with a standard deviation of 2.3 days. A random sample of size 12 from the second vendor yielded an average delay time of 3.4 days with a standard deviation of 6.2 days.

a. Find a 90% confidence interval for the ratio of the variances of the delay times for the two vendors.

b. Find a 95% confidence interval for the differences in the average delay times for the two vendors.

c. Can we conclude that the first vendor has a smaller variability regarding delay times than the

second? Use a significance level of .05.

[10]

ET ZC432 (EC-2 REGULAR)

FIRST SEMESTER 2008-2009

PAGE 2

Q.4

Consider the assembly of 3 components shown in figure. Tolerances for the three components are given below:

 Components Mean Length (in cm) Tolerances ( in cm) A 10 10 +/- 0.5 B 4 4 +/- 0.2 C 5 5 +/- 0.1

Gap

B

C

A

Assume that the tolerances on the component are independent of each other and that the lengths of the components are normally distributed.

a. What is the tolerance of the gap?

b. Assuming normality, if specifications of the gap are 0.9 +/- 0.201 cm, what proportion of assembly will not meet specifications?

c. Suppose the desirable specifications on the gap are 2 +/- 0.02 cm. Assume the mean lengths

of A, B and C to be 11.1, 4.2 and 5.3 cm, respectively. Also assume the natural tolerances to be +/-0.5, +/-0.2 and +/-0.1 cm for A, B and C, respectively. Find the proportion of

Q.5

Q.6

assemblies that will not be acceptable.

[10]

A double sampling plan is given as follows: N = 1200, n 1 = 50, c 1 = 1, r 1 = 4, n 2 = 110, c 2 = 5, r 2 =

7. Find the probability of accepting a lot that are 4 % nonconforming? What is the probability of

rejecting a lot on first sample? Use Poisson’s distribution.

[8]

Consider the seven component system shown in the figure. Reliability of components are R A = 0.96, R B = 0.92, R C = 0.94, R D = 0.89, R E = 0.95, R F = 0.88, R G = 0.90.

A
E
F
C
D
G
B

a. Find the reliability of the system.

b. Assuming time to failure for each component has exponential distribution, the failure rate for each components are λ A = 0.0005 / hr, λ B = 0.0005 / hr, λ C = 0.0003 / hr, λ D = 0.0008 / hr, λ E = 0.0004 / hr, λ F = 0.006 / hr, λ G = 0.0064 / hr. Find the reliability of the system after 1000 hours? What is the mean time to failure of the system? [8]

Q.7

Compare and contrast the quality philosophies proposed by Deming, Crosby and Juran. Present