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EPM 212 Metrology and Quality Control Quiz 1

Liew Shu Yan 133482 Mechanical

Q1(a) (i) Total quality management is an organizational approach to maintain quality for customers,
suppliers and all people in the organization, not just the quality control personnel. It is a never-ending
quest to improve quality, whereby everyone from top management to bottom are required to be
committed to a quality standard. Total quality management focuses on quality management.

The Taguchi Method of quality control is an approach to engineering that emphasizes the roles of
research and development, product design and product development in reducing the occurrence of
defects and failures in products. The Taguchi method considers design to be more important than the
manufacturing process in quality control and tries to eliminate variances in production before they
can occur. Taguchi method is focused on creating a robust design in which performance and functions
are relatively sensitive to variation in working environments. Taguchi method focuses on products and
their efficiency in production.

(ii) Data collection, utilization and dissemination of quality information is best accomplished when the
information is incorporated into an IT system. It maintains relationship with many activities, such as
inventory control, purchasing, design, marketing, accounting and production control. Computers are
well suited for the collection of data with faster data transmissions, fewer errors and lower collection
costs. A vast amount of data can be collected and analyzed, and the records are to be retained and
stored efficiently in remote terminals. While some quality information is merely stored in the
computer for a retrieval in the future, most of the information is analyzed, reduced to a meaningful
amount, and disseminated in the form of a report. These activities of analysis, reduction and reporting
are programmed to occur automatically or on command by the computer operator.

Q1(b)

Fracture Stress Hardness


349 70
368 40
301 55
340 78
308 64
Recycled Aluminium Cast
348 86
354 71 100
90
313 53
80
322 82
70
334 67
Hardness

60
292 51 50
377 70 40
247 56 30
298 60 20
287 72 10
345 88 0
0 50 100 150 200 250 300 350 400
380 95
Fracture Stress
257 51
258 75
293 53
The scatter diagram shows a low positive correlation between Fracture Stress and Hardness.
EPM 212 Metrology and Quality Control Quiz 1
Liew Shu Yan 133482 Mechanical

Q1(c)

Subgroup X1 X2 X3 X4 X5 X bar Range


1 9.5 9.2 9.1 9.3 9.7 9.36 0.6
2 10.1 8.9 10 9.3 9.6 9.58 1.2
3 10.0 8.7 9.4 9.5 9.7 9.46 1.3
4 9.2 9.1 9.7 10.1 9.6 9.54 1
5 9.7 9.2 10 9.7 9.8 9.68 0.8
6 9.8 9.3 9.3 9.1 9.3 9.36 0.7
7 10.0 9.2 9.3 9.4 9.5 9.48 0.8
8 9.1 9.1 9.5 9.4 9.3 9.28 0.4
9 9.5 8.9 9 9 8.9 9.06 0.6
10 8.9 9.7 9.5 9 9.6 9.34 0.8
(i)
From calculation, X double bar= 9.414 and R bar = 0.82,
Sigma =R bar/d2 = 0.82/2.326= 0.3525
Process capability = 6 sigma= 2.11522

Potential Capability =Cp = USL-LSL/6sigma = (10-8)/2.11522=0.94553


Min(USL-Xbar)=10-9.414=0.586
Actual Capability = Cpk = 0.586/3sigma = 0.55414

(ii) Z(USL) =(10-9.414)/0.3525=1.6624


Z(LSL) =(9.414-8)/0.3525=4.0113

Q2 (a) Tolerance design is the dimension accuracy which the error is accounted for in the
permissible variation range and the quality is based on tolerance. Tolerance Design seek to
minimize dispersion while at the same time meeting a design target. Tolerance and Parameter
design techniques are usually used together as part of a quality design. As tolerances are tightened,
a better product is formed. However, production costs may increase. Ideally, tolerances should be
defined by balancing the precision needed with the cost of production.

(b) (i) No. The control chart is a time series plot that will monitor the process changes associated
with the particular characteristic over time.
EPM 212 Metrology and Quality Control Quiz 1
Liew Shu Yan 133482 Mechanical

(ii)

Part X bar Std Dev


A1 50 49 50 49.66667 0.577
A2 52 52 51 51.66667 0.577
A3 53 50 50 51 1.732
A4 49 51 50 50 1.000
A5 48 49 48 48.33333 0.377

B1 50 48 51 49.66667 1.528
B2 51 51 51 51 0
B3 54 52 51 52.33333 1.528
B4 48 50 51 49.66667 1.528
B5 48 49 48 48.33333 0.577
EPM 212 Metrology and Quality Control Quiz 1
Liew Shu Yan 133482 Mechanical

Q3(a)

Control Charts

Variable Attribute
Control Charts Control Charts

x-bar and R p-chart

x-tilda and R np-chart

X-bar and s c-chart

X and MR u-chart

Run Charts
EPM 212 Metrology and Quality Control Quiz 1
Liew Shu Yan 133482 Mechanical

Q3(b)(i)

Sample Avg Relative


No Mass Freq Mass of Sample
1 1.6069 0.1064 0.14
2 1.49512 0.0990 0.12

Relative Frequency
3 1.4865 0.0984 0.1
4 1.47118 0.0974 0.08

5 1.48822 0.0985 0.06


0.04
6 1.4491 0.0959
0.02
7 1.57918 0.1046
0
8 1.50512 0.0987 1 2 3 4 5 6 7 8 9 10
9 1.5076 0.0998 Sample Number
10 1.51348 0.1002

Total Freq= 75.512


Avg Total Freq= 1.51024

Cumulative Frequency
Cumulative
Freq 1.2

0.1064 1
0.2054
0.8
0.3038
0.4012 0.6

0.49973 0.4
0.59568
0.2
0.70028
0.79988 0
1 2 3 4 5 6 7 8 9 10
0.89971
Sample
0.99991

The graph of cumulative frequency gradually increases and the final value is lower than
1, at 0.99991. This shows that the process is in control.

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