Name: ID:

Quality Engineering
Test Exam – April 2019
Time Allowed: 1:30 hours
Instructor: Dr. Attia Gomaa Max. Marks: 60
Number of questions: 7 No. of pages: 7

Question (1): Six Sigma Tools - Sample Analysis:

The weekly production information is as follows:

• Nominal diameter = 8.4 ± 0.2 mm Lot Size = N = 1000 unit
• Single Sample Sample Size: 30 Units Target Defect ≤ 1 unit from 30

# M/c #1 M/c #2 M/c #3 M/c #4 M/c #5

1 8.5 8.5 8.4 8.6 8.5
2 8.8 8.6 8.5 8.4 8.5
3 8.5 8.5 8.4 8.5 8.4
4 8.5 8.4 8.5 8.1 8.6
5 8.4 8.6 8.5 8.4 8.6
6 8.7 8.4 8.5 8.6 8.5
(Mean = 8.497 Sigma  = 0.12172 )

Based on this information, discuss the following:

a) Variance Analysis b) Normal Distribution Test
c) Process Control Chart d) Average and Range Charts

(Page 1/7)
Question (2): Six Sigma Tools - Process Capability Analysis:

A metal-cutting operation has a target value of 100±1 and the process average is 99.7 with a
standard deviation of 0.26. Based on this information discuss the following:
a) Process capability
b) Design for 3 Sigma (target control chart)

(Page 2/7)
 Question (3): Six Sigma Tools - Defect Analysis:

A Pipeline project has the following defects while producing 10,000 welding joints:

ID Defect Description Defect Freq. Repair Cost / Joint

A Incomplete Joint 20 30
B Improper Fusion 8 30
C Overlap 12 20
D Insufficient Penetration 14 30
E Pits 22 20
F Porosity 30 30
G Vertical Crack 10 40
H Under Bead Crack 6 40
I Irregular Weld 16 10

Based on this information:

a) Construct the Pareto chart & rule 80/20
b) Construct the fishbone diagram

(Page 3/7)
Question #4: Six Sigma Tools - Reliability Analysis:

A water Pump station as shown in the following figure:

Working Condition = 20,000 Hours

Motor Coupling Pump
Number of failures 2 3 5

Based on this information, calculate the following:

• MTBF (hour/failure)
• Failure Rate (failure/hour)
• Reliability analysis after 2000, 4000, 8000 hours
• Based on the reliability analysis, propose the maintenance program

(Page 4/7)
 Question #5: Lean Tools – Process Time Analysis:
Based on the following information; discuss the time analysis based on lean approach:
Actual Non-
Value Target Main
# Activity Time Value Waste
Added Time Recommendations
(min) Added
1 W/o 30
Preparation
2 Material 30
Receipt
3 Material Inspect 20

4 Material 40
Handling
5 Machine startup 30

6 Process (A) 120

7 failure & repair 60

8 Machine startup 30

9 Process (A) 60

10 Inspection 40

11 Rework 60

12 Process (B) 80

13 Inspection 40

14 Rework 40

15 Packing Process 60

16 Material 40
Handling
17 W/o Close-Out 30

Total Time
%
Conclusion:

(Page 5/7)
 Question #6: Lean Tools – OEE Analysis:

The operation information for a petrochemical industry is as follows:

Working Hours 24 hr/day
Working Days 365 Days
Planned Downtime 10 Days
Unplanned Downtime 6 Days
Standard Rate 20 units/hr
Actual Operating Time 8,000 Hours
Total Production Quantity 110,000 units
Reject/Scrap Quantity 10,000 units

Based on this information; discuss the following:

• Process time analysis chart
• Availability & Reliability & OEE

(Page 6/7)
Question #7: Risk Analysis:
Briefly discuss the risk breakdown structure in your field:
Project / Product: Criticality:

Objective Risk Effect Action Owner

1) Material defects High Defect % QA / QC Quality
Quality

(Page 7/7)