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Given,
N=20,000,
C1= 1,
1 R1= 4
n1= 25,
n2= 30,
C2= 4,
4 R2= 6
n3= 35,
C3= 7,
7 R3= 8
Steps : i)
Inspect items of first sample of size 25,
25
ii)
If no. of defectives is 0 or 1, Accept the lot
iii)
If no. of defectives is 4 or more,
Reject the lot
more
iv)
If no. of defectives is 2 or 3, Inspect items of second sample of size
30 and then,
1) If no. of defectives in the combined sample (25 + 30) does not exceed
4,
Accept the lot
2) If no. of defectives in combined sample (25 + 30) is 6 or more,
more Reject
the lot.
3) If no. of defectives in the combined sample (25 + 30) is 5, Inspect
items
of third sample of size 35,
35 and then,
(a) If no. of defectives in combined sample (25 + 30 + 35) does not exceed
7, Accept the lot
(b) If no. of defectives in combined sample (25 + 30 + 35) is 8 or more,
Reject the lot.
n2= 30,
[contd..]
n3= 35,
C2= 4,
4 R 2= 6
C3= 7,
7 R 3= 8
4) Sample 1 : d1 = 2
d3 = 0 or 1 or 2
5) Sample 1 : d1 = 3
and then Sample 2 : d2 = 2
Sample 3 :
d3 = 0 or 1 or 2
(d 1 + d 2 = 5)
and then
prescribed for the lot (offered for inspection), that can allow accepting the lot .
or
C = n x (% AQL / 100)
AQL values usually lie between 0.5% and 3.0%.
value is prefixed and mutually accepted by both Buyer and seller.
AQL
or
R = n x (% RQL / 100)
(LTPD)].
LTPD
Pa
100%
89%
Producers Risk ()
= 100% 89%
= 11% (Rejection
probability)
35%
100% Rejection
Probability
90% Rejection
Probability
10%
0.01 (1%)
AQL
0.03 (3%)
(Fd) Fraction
0.05 (5%)
RQL
8%
Defectives
(% Defective)
Pa = Probability of Acceptance,
Total no. of items in outgoing lots = K.N (at Fraction Defective of Fd)
Total no. of defectives originally = K.N.Fd
Total no. of defectives in accepted lots = K.N.Fd x Pa
AOQ = K. N.Fd .Pa
= K. N. Fd .Pa = Fd . Pa
K.N.Pa + K.N.(1 Pa)
K.N
AOQ = Fd . Pa
(vi)
AOQL
Max. AOQ
*
F
d
Fd (Fraction Defective)
(vii)
Producers Risk ( ) :
It is the probability of rejecting a good quality (AQL quality)
quality lot in the Sampling
Plan. The risk of rejecting the lots of AQL quality in a sampling plan, should be smaller
than the designated Producers Risk ().
Rejecting a lot at AQL is AT PRODUCERS RISK.
(viii)
Consumers Risk () :
It is the probability of accepting a bad quality (RQL quality)
quality lot in the Sampling
Plan. The risk of accepting the lots of RQL quality in the sampling plan, should be
smaller than designated Consumer Risk().
Accepting a lot at RQL is AT CONSUMERS RISK.
The sample size for inspection is 1500 pieces for the lot of
40,000. In inspection of 1500 items of the sample-size, if
number of defective items found does not exceed the
Acceptance Number (C) the whole lot is accepted.
AQL being 2%
of sample size,
Problem 4 : Find the AOQL and show it on AOQ vs Percent Defectives curve,
based on the data given below, as available from OC Curve.
Fd
(%)
Pa (%)
0.4
96.3
1.0
82.7
1.4
71.8
1.6
66.3
1.8
61.0
2.0
55.8
2.2
50.9
2.5
44.1
3.0
34.3
3.5
26.2
4.0
19.9
Solution 4 :
Given
Page 1of 2
Solution:
Fd
(%)
Pa (%)
0.4
Fd(%)
Pa
96.3
0.4
0.963
0.385
1.0
82.7
1.0
0.827
0.827
1.4
71.8
1.4
0.718
1.005
1.6
66.3
1.6
0.663
1.061
1.8
61.0
1.8
0.610
1.098
2.0
55.8
2.0
0.558
1.116
2.2
50.9
2.2
0.509
2.5
44.1
2.5
0.441
1.102
3.0
34.3
3.0
0.343
1.029
3.5
26.2
3.5
0.262
0.917
4.0
19.9
4.0
0.199
0.796
AOQL =
Solution 4 :
Page 2 of 2
AOQ curve
1.5
1.2
AOQL
1.12
1.0
(with rectification)
0.796
0.385
AOQ = Fd x Pa
Fd (Fraction Defective)
0.004
0.01
0.022
0.04
CONTROL
CHARTS
&
CONTROL
LIMITS
Non-conformities
where i = 1 to N
Ri = ( X max Xmin)
R = ( Ri ) N
where i = 1 to N
= R d2
_
= S C2
X Chart and R-Chart
X Chart
R-Chart
=
X
X + A2.R
_
D4 . R
X A2.R
_
D3 . R
UCL
=
X
_
R
LCL
_
X - Chart
UCL
LCL
N
R - Chart
X Chart
R-Chart
=
X
_
R
X + A2.R
_
D4 . R
X A2.R
_
D3 . R
S-Chart
_
X Chart and SChart
Central Line (CL)
Upper Control Limit
(UCL)
X Chart
=
X
_
S
X + A3.S
_
B4 . S
Control
Limit (LCL)applicable
= over X R chart, when _
# [ X Lower
S charts
are preferably
X A3.S
B3 . S
(1) Sample size, n > 10,
(2) Tight control of Process Variability is needed, and
(3) Sample size n varies.]
A2
D3
D4
A3
B3
B4
d2
C2
1.88
3.27
2.66
3.27
1.128
0.7979
1.02
2.57
1.95
2.57
1.693
0.8862
0.73
2.28
1.63
2.27
2.059
0.9213
0.58
2.11
1.43
2.09
2.326
0.9400
0.48
2.00
1.29
0.03
1.97
2.534
0.9515
0.42
0.08
1.92
1.18
0.12
1.88
2.704
0.9594
0.37
0.14
1.86
1.10
0.19
1.81
2.847
0.9650
0.34
0.18
1.82
1.03
0.24
1.76
2.970
0.9693
10
0.31
0.22
1.78
0.98
0.28
1.72
3.078
0.9727
CL =
UCL =
LCL =
CAUSES OF VARITION
OF MEASUREMENTS
Variation in measurement (quality) can be caused in two ways,
i)
Assignable Causes
ii)
Natural or Chance or Random Causes.
ASSIGNABLE CAUSES
Basic Nature :
1) For Assignable Causes the variations are generally greater in
magnitude (in comparison to Natural Causes)
2) The variations do not follow Normal Statistics.
Statistics
3) The Assignable causes & variations are not inevitable.
inevitable
4) Assignable Causes of variation are generally easily traceable &
identifiable
5)
Assignable Causes of variation normally can be avoided /
rectified / eliminated.
eliminated
6)
If Assignable Causes are not rectified, the process becomes
Out of Control.
Control
CAUSES OF VARITION
Faulty process
Quality of raw materials and/or components,
components
Wear & Tear of the machine and equipment
Operating Condition of Equipment / machineries, like vibration,
leveling defect, defective centering, non-alignment, etc
Improper fixing / fitting of tools
Wrong tools
Wrong setting of machine
Faulty jigs and fixtures
Improper Maintenance
Use of uncalibrated or poorly calibrated instrument, gauges,
gauges etc.
Faulty Environmental Condition of working place (improper
lighting & ventilation,
ventilatio dust,
dust smoke,
smoke temperature variation, toxic
or corrosive atmosphere, humidity, etc),
Operating Condition of Instrumentation & Control,
Inadequate Skill of workers / operators,
Mental condition / Mood of workers / operators,
Carelessness and mistake on the part of operators,
CAUSES OF VARITION
Distinguish between
Natural Causes and Assignable Causes
Natural Error Assignable Error
1)
2)
3)
4)
5)
6)
7)
Sampling Error
Testing Process / Method Error
Error in Measuring devices or Instrument
Personal Error.
Error
-3
-2
=
X ()
68.28%
95.46%
99.73%
3 Deviation
Limits
99.99966% ie 3.4 defects per million population come under the range
( 4.5 ) . So, Six Sigma range covers 3.4 defects per million
population, even with a shift of Mean by 1.5 Sigma.
UNTL = Process CL + 3
LNTL = Process CL 3
(Natural)
Natural Process SPREAD = (UNTL LNTL)
LNTL = 6
PROCESS CAPABILITY RATIO
(PCR) = Specified Spread.
Spread
Process Spread
TOLERANCE
Tolerance is the acceptable / allowed limits of variations of the measurements
(dimensions, strength, properties, finish, etc) of the items of the lot.
Tolerance Limits are the maximum variations of the measurement those can
be acceptable / allowed, above (Upper Control Limit) or below (Lower Control
Limit) the corresponding specified measurement. Example :
+ 0.2
+ 0.8
+10
Diameter 455 mm, Cr content 14
%, Strength 540
kg/cm2
0.3
0. 5
0
Tolerance may be : (i) Natural Tolerance
and/or
Natural Tolerance : If the process is Under Control (ie the variations are
small and follow statistical laws), the Upper Control Level (UCL) and the
Lower Control Limit (LCL) together indicate the Natural Tolerance.
The gap between Natural Tolerance Limits UCL & LCL (ie 6 ) is BAND.
Specified Tolerance : The tolerance limits (U & L) predefined or
specified by the designer or the user of the product (depending on the
quality needed to fit it in its use) is termed as Specified Tolerance.
Specified Tolerance is not directly related to or dependent on Natural
Tolerance ie Natural Control Limits. Specified Tolerance is important and
considered in QC of industrial Products.
The gap between Specified Tolerance Limits USL & LSL is SPREAD.
at position 1.
2) If 6 = S
Strict Centering care to be taken
=
to keep the Control (Centre) Line X
perfectly at the Centre Line of Spread.
It is also better to relax the Specified
Tolerance to make S> 6 . Position 2
is shifted and kept at position 1.
3) If 6 > S
=
X
USL
CL
=
X
LSL
USL
1
6
=
X 6
CL
=