5-4.

Sample Number

x1

x2

0.0629

0.0636

0.064

0.063

0.0631

0.0622

0.0628

0.0631

0.0633

0.0634

0.063

0.0619

0.0613

x3

max

min

0.0635

0.064

0.0629

0.0011

0.062766667

0.0631

0.0622

0.0009

0.063066667

0.0633

0.0628

0.0005

0.0631

0.063166667

0.0634

0.063

0.0004

0.0628

0.063

0.062566667

0.063

0.0619

0.0011

0.0629

0.0634

0.062533333

0.0634

0.0613

0.0021

0.063

0.0639

0.0625

0.063133333

0.0639

0.0625

0.0014

0.0628

0.0627

0.0622

0.062566667

0.0628

0.0622

0.0006

0.0623

0.0626

0.0633

0.062733333

0.0633

0.0623

0.001

10

0.0631

0.0631

0.0633

0.063166667

0.0633

0.0631

0.0002

11

0.0635

0.063

0.0638

0.063433333

0.0638

0.063

0.0008

12

0.0623

0.063

0.063

0.062766667

0.063

0.0623

0.0007

13

0.0635

0.0631

0.063

0.0632

0.0635

0.063

0.0005

14

0.0645

0.064

0.0631

0.063866667

0.0645

0.0631

0.0014

15

0.0619

0.0644

0.0632

0.063166667

0.0644

0.0619

0.0025

16

0.0631

0.0627

0.063

0.062933333

0.0631

0.0627

0.0004

17

0.0616

0.0623

0.0631

0.062333333

0.0631

0.0616

0.0015

18

0.0630

0.063

0.0626

0.062866667

0.063

0.0626

0.0004

19

0.0636

0.0631

0.0629

0.0632

0.0636

0.0629

0.0007

20

0.0640

0.0635

0.0629

0.063466667

0.064

0.0629

0.0011

21

0.0628

0.0625

0.0616

0.0623

0.0628

0.0616

0.0012

22

0.0615

0.0625

0.0619

0.061966667

0.0625

0.0615

0.001

23

0.0630

0.0632

0.063

0.063066667

0.0632

0.063

0.0002

24

0.0635

0.0629

0.0635

0.0633

0.0635

0.0629

0.0006

25

0.0623

0.0629

0.063

0.062733333

0.063

0.0623

0.062952

CTQ: thickness of a printed circuit board (in inches)

m = 25 ; n = 3
(a) Computed from the data:
;
Values of constants from Appendix VI of the book:
Control limits for R control chart:
UCL=
CL=
LCL =
Control limits for control chart:

UCL =
CL=

LCL=

0.0007
0.00092

.0638932

control chart

.064

.062952

.0635
.063
.062

.0625

CL

LCL
0

10

15

20

25

15

20

25

.0620108

UCL

Subgroup

.002369

UCL

.001

.00092

.0015

.002

.0025

R control chart

LCL

.0005

CL

10
Subgroup

No, the process is out of statistical control. Both the and R control charts have 1 point which is outside
the 3 control limits.
(b) Estimation of process standard deviation:

(c) The 6 sigma limits may contain nearly all the process measurement.

For R chart: UCL =

(
) = 0.003815

LCL =
For control chart: UCL =
LCL =

) = -0.00198

0.064834
0.06107

(d) Given specifications: 0.0630 in. 0.0015 in.

USL= 0.0630 + 0.00015 = 0.0645
LSL = 0.0630 0.00015 = 0.0615

Since
, the process uses up more than 100 % of the tolerance band. Large number of
nonconforming units will be produced.

5-5.
Sample
Number
1

x1

x2

x3

x4

x5

x6

x7

x8

x9

x10

x-bar

stdev

max

min

ssquared

2.5

0.5

-1

-1

0.5

1.5

0.5

-1.5

0.5

1.333333

2.5

-1.5

1.777778

0.5

1.5

-1

1.5

-1

0.45

0.926463

1.5

-1

2.5

0.858333

1.5

-1

-1.5

-1

-1

-1

-0.1

1.125463

1.5

-1.5

1.266667

0.5

-2

-1

1.5

-1.5

-2

-1.5

-0.6

1.173788

1.5

-2

3.5

1.377778

-0.5

0.5

-0.5

-0.5

0.471405

-0.5

1.5

0.222222

-0.5

0.5

-1

-2

0.971825

-2

0.944444

-1

-1

-1

1.5

0.05

0.895979

1.5

-1

2.5

0.802778

-1.5

-0.5

1.5

-1

0.5

-0.5

-0.15

0.818196

1.5

-1.5

0.669444

-2

-1.5

1.5

1.5

0.5

0.2

1.183216

1.5

-2

3.5

1.4

10

-0.5

3.5

-1

-1.5

-1.5

-1

-1

0.5

-0.15

1.528434

3.5

-1.5

2.336111

11

1.5

-1.5

0.5

-0.5

-1

0.3

1.206464

-1.5

3.5

1.455556

12

-2

-0.5

-0.5

1.5

0.5

-1

1.154701

-2

1.333333

13

-1

-0.5

-0.5

-1

0.5

0.5

-1.5

-1

-1

-0.55

0.68516

0.5

-1.5

0.469444

14

0.5

-1

-0.5

-2

-1

-1.5

1.5

1.5

-0.15

1.248332

1.5

-2

3.5

1.558333

15

1.5

1.5

-1

-2

-1.5

0.15

1.270389

1.5

-2

3.5

1.613889

-0.00333

1.06621

3.2

1.205741

CTQ: fill volume of soft drink beverage bottles

m = 15 samples ; n= 10
(a) Computed from the data:
For control chart :
UCL

CL=
LCL =

1.06621 ;
1.036221259
-1.042887925

For s control chart :

UCL = 1.716 (1.06621) =1.829616082
CL = 1.06621
LCL=
1.06621) = 0.302803594

Average Volume

1.5
1

UCL, 1.037

0.5
0
1

9 10 11 12 13 14 15

CL, -0.003

-0.5
LCL, -1.043
-1
-1.5

Subgroup

Standard Deviation

2
UCL, 1.830

1.5
1

CL, 1.066

0.5

LCL, 0.302

0
1

9 10 11 12 13 14 15
Subgroup

(b) Control limits for R chart:

UCL=
CL=
LCL =

6
UCL, 5.686

5
Range

4
3

CL, 3.200

2
LCL, 0.714

1
0
1

9 10 11 12 13 14 15

Subgroup

The R control chart seems to look the same as the s chart in (a) although it has higher control limits
compared to the latter. Both show that all points are in control.
(c)

control chart:

UCL=
CL= =1.136803
LCL= =

2.979606

0.219142

3
UCL, 2.979606

s-squared

2.5
2
1.5

CL, 1.136803

1
0.5

LCL, 0.219142

0
1

9 10 11 12 13 14 15

Subgroup

The high points and low points in and s control chart are mostly the same although they are higher in
than in s control chart. It can also be seen that there is one point in
that is in the lower control
limit and is actually almost outside the limit; this might suggest an out of control signal in the process.
5-13.
m= 50 subgroups
n= 4 items

(a)

s-chart: UCL= 2.266 (

CL= = 1.44
LCL=
control chart:
= 1000/50 = 20
UCL=
CL= = 20
LCL=

= 20 + (1.628)(1.44) = 22.34432
= 20 - (1.628)(1.44) = 17.65568

(b) natural tolerance limits:

= =
UNTL= + 3 = + 3 = 20 + 3(1.56300879) = 24.68903
LNTL = - 3 = - 3 = 20 - 3(1.56300879) = 15.31097
(c) specification limits:
USL = 19 + 4= 23
LSL = 19 -4 = 15

0.85305556

Since
, the process uses up more than 100 % of the tolerance band. Thus, large number of
nonconforming units will be produced. Moreover, 117.23% of the specification band is being used by
the process.
5-30.
CTQ: tensile strength of a metal part
m= 30 samples
n= 6 parts

(a)

;
Control limits for R control chart:
UCL=
CL=
LCL =
Control limits for control chart:

UCL =
CL=

LCL=

(b)
Process Capability:

i.

USL= 205 ; LSL = 195

p= P { x < 195} + P { x> 205}
=*
*
+
= 0.005638 + 1 0.994362
= 0.01127687

Thus, about 1.1% of the tensile strength of the metal parts produced will be outside of the
specifications.
ii.

0.84466667

<1, process uses up more than 100% of the tolerance band, thus, a large number of nonconforming
units will be produced. Moreover, 118.4% of the specification band is being used by the process.
(c)

=(L-k ) - (-L-k )
= (3+0.5 ) - (-3+ 0.5 )
= (4.2414014) (-1.7586)
= 0.99998889 0.039323
= 0.960666

5-34.
CTQ: cigar lighter detent
Specifications: (0.3200 in., 0.3220 in.)

Sample
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

x1

x2

x3

x4

x5

max

min

x-bar

1
9
0
1
-3
-7
-3
0
2
0
-3
-16
-6
-3
-1

9
4
9
1
0
2
-1
-2
0
2
-2
2
-3
-5
-1

6
3
0
0
-1
0
-1
-3
-1
-1
-1
0
0
5
-1

9
0
3
2
0
0
0
-3
-3
-1
-1
-4
0
0
-2

6
3
2
1
-4
2
-2
-2
-1
2
2
-1
-8
5
-1

9
9
9
2
0
2
0
0
2
2
2
2
0
5
-1

1
0
0
0
-4
-7
-3
-3
-3
-1
-3
-16
-8
-5
-2

8
9
9
2
4
9
3
3
5
3
5
18
8
10
1
6.466667

6.2
3.8
2.8
1
-1.6
-0.6
-1.4
-2
-0.6
0.4
-1
-3.8
-3.4
0.4
-1.2
0.06667

Control limits for R control chart:

UCL=
CL=
LCL =
20

Range

15
UCL, 13.673
10
5

CL, 6.467
LCL, 0.000

0
1

9 10 11 12 13 14 15

Subgroup

There is one point outside the control limits suggesting a signal for an out of control process.
(b) I would recommend using 6 for the control limits:

For R chart: UCL =

LCL =
(c)

(
(

) = 20.87905
) = -7.9457 ~ 0

(d) Process capability:

i.
USL= 0.3220 ; LSL =0.3200
p= P { x < 0.3200} + P { x> 0.3220}
=*
*
+
= 0.555307 + 1 0.555591
= 0.999716

Thus, about 99.97% of the cigar lighter detents produced will be outside of the
specifications.
ii.

0.00012

<1, process uses up more than 100% of the tolerance band, thus, a large number of nonconforming
units will be produced. Moreover, the process uses up about 834049% of the specification band.
5-40.
UCL= 104 ; Center line= 100; LCL = 96 ; n=5
CTQ N
k=1.15
=(L-k ) - (-L-k )
= (3-1.15 ) - (-3-1.15 )
= (0.428522) (-5.57148)
= 0.665864377 0.000000012
= 0.665864364
Probability that the shift will be detected by at least the 3rd point:

5-41.
2.992797
Thus, the expected number of samples taken to detect the shift is 3.
5-44.
Specifications: USL= 620 ; LSL= 580 ; n=9

(a)

1.111

>1, process uses up less than 100% of the tolerance band, thus, a small number of nonconforming
units will be produced. Moreover only 90% of the specification band is being used by the process.
(b) assuming that is constant
k

(3-k )

(-3-k )

0.1

0.996533

0.000483424

0.99605

(3-k )

(-3-k )

2.75

7.6E-08

1.15796E-29

7.6E-08

0.2

0.991802

0.000159109

0.75

0.773373

7.60496E-08

0.991643

9.87E-10

1.77648E-33

9.87E-10

0.773373

3.25

7.39E-12

1.55873E-37

7.39E-12

0.5

9.86588E-10

0.5

3.5

3.19E-14

7.81881E-42

3.19E-14

1.25

0.226627

7.39226E-12

0.226627

3.75

7.92E-17

2.24141E-46

7.92E-17

1.5

0.066807

3.19089E-14

0.066807

1.13E-19

3.67097E-51

1.13E-19

1.75

0.012224

7.91973E-17

0.012224

4.25

9.22E-23

3.43407E-56

9.22E-23

0.00135

1.12859E-19

0.00135

4.5

4.32E-26

1.83446E-61

4.32E-26

2.25

8.84E-05

9.22341E-23

8.84E-05

4.75

1.16E-29

5.59497E-67

1.16E-29

2.5

3.4E-06

4.31901E-26

3.4E-06

1.78E-33

9.74095E-73

1.78E-33

.8
n=9

.6

.4

.2

0
0

3
k

5-47.
control chart:
UCL= 815 ; Center line= 800; LCL = 785 ; n=4
control chart:
UCL= 46.98 ; Center line=20.59; LCL = 0

=(L-k ) - (-L-k )
= (3+1 ) - (-3+ )
= (5) (-1)
= 0.999999713 0.158655
= 0.841344459
The probability of detecting the shift on the first subsequent sample is 1- =1-0.841344459= 0.158656.
5-48.
6.302962987
That is, the expected number of samples taken to detect a shift of -1 with n=4 is 6.
5-67.

(a)
(b)
(c)

(d)
obs

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

10.07
10.47
9.45
9.44
8.99
7.74
10.63
9.78
9.37
9.95
12.04
10.93
11.54
9.58
8.8
12.94
10.78
11.26
9.48
11.28
12.54
11.48
13.26
11.1
10.82

span
2

span
3

span
4

span
5

span
6

span
7

span
8

span
9

span
10

0.4
1.02
0.01
0.45
1.25
2.89
0.85
0.41
0.58
2.09
1.11
0.61
1.96
0.78
4.14
2.16
0.48
1.78
1.8
1.26
1.06
1.78
2.16
0.28
1.305
1.157

1.02
1.03
0.46
1.7
2.89
2.89
1.26
0.58
2.67
2.09
1.11
1.96
2.74
4.14
4.14
2.16
1.78
1.8
3.06
1.26
1.78
2.16
2.44
2.049
1.21

1.03
1.48
1.71
2.89
2.89
2.89
1.26
2.67
2.67
2.09
2.46
2.74
4.14
4.14
4.14
3.46
1.8
3.06
3.06
1.98
2.16
2.44
2.598
1.262

1.48
2.73
2.89
2.89
2.89
2.89
2.67
2.67
2.67
2.46
3.24
4.14
4.14
4.14
4.14
3.46
3.06
3.06
3.78
2.16
2.44
3.048
1.31

2.89
2.89
2.89
2.89
4.3
4.3
2.67
2.67
3.24
4.14
4.14
4.14
4.14
4.14
4.14
3.46
3.78
3.78
3.78
2.711
3.555
1.403

2.89
2.89
2.89
2.89
4.3
4.3
2.67
2.67
3.24
4.14
4.14
4.14
4.14
4.14
4.14
3.46
3.78
3.78
3.78
3.599
1.331

2.89
2.89
2.89
4.3
4.3
4.3
2.67
3.24
4.14
4.14
4.14
4.14
4.14
4.14
4.14
3.78
3.78
3.78
3.767
1.323

2.89
2.89
4.3
4.3
4.3
4.3
3.24
4.14
4.14
4.14
4.14
4.14
4.14
4.14
4.46
3.78
3.78
3.954
1.331

2.89
4.3
4.3
4.3
4.3
4.3
4.14
4.14
4.14
4.14
4.14
4.14
4.14
4.46
4.46
3.78
4.1294
1.3416

obs

10.07

10.47

9.45

9.44

8.99

7.74

10.63

9.78

9.37

span 11

span 12

span 13

span 14

span 15

span 16

span 17

span 18

span 19

span 20

10

9.95

11

12.04

4.3

12

10.93

4.3

4.3

13

11.54

4.3

4.3

4.3

14

9.58

4.3

4.3

4.3

4.3

15

8.8

4.3

4.3

4.3

4.3

4.3

16

12.94

5.2

5.2

5.2

5.2

5.2

5.2

17

10.78

4.14

5.2

5.2

5.2

5.2

5.2

5.2

18

11.26

4.14

4.14

5.2

5.2

5.2

5.2

5.2

5.2

19

9.48

4.14

4.14

4.14

5.2

5.2

5.2

5.2

5.2

5.2

20

11.28

4.14

4.14

4.14

4.14

5.2

5.2

5.2

5.2

5.2

5.2

21

12.54

4.14

4.14

4.14

4.14

4.14

5.2

5.2

5.2

5.2

5.2

22

11.48

4.14

4.14

4.14

4.14

4.14

4.14

5.2

5.2

5.2

5.2

23

13.26

4.46

4.46

4.46

4.46

4.46

4.46

4.46

5.52

5.52

5.52

24

11.1

4.46

4.46

4.46

4.46

4.46

4.46

4.46

4.46

5.52

5.52

25

10.82

4.46

4.46

4.46

4.46

4.46

4.46

4.46

4.46

4.46

5.52

4.328

4.405714

4.495385

4.6

4.723636

4.872

4.953333

5.055

5.185714

5.36

1.364009

1.352276

1.347537

1.350161

1.360494

1.379388

1.380528

1.388736

1.405724

1.435074