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This is file Q8IM13B.DOC - The second of 5 files for solutions to this chapter.

NOTE: THERE IS AN ARTICLE IN QUALITY ENGINEERING THAT PROVIDES


EXAMPLES OF PROJECTS AN INSTRUCTOR CAN DO IN CLASS:
Marilyn Hart. Learning by Doing: A Series of Hands-on Projects for SPC, Quality
Engineering, 17:127137, 2005
SOLUTIONS TO PROBLEMS
Author's Note: In this chapter, printouts and summarized solutions are taken
from Excel spreadsheets. Note that the templates have been tailored for
the problem size in each problem solution, whereas the blank templates are
designed as one size fits all versions. Typically, those templates are
designed for problems of 25 or 50 samples. They may be modified by
unlocking the protection on the spreadsheet. It would be a good idea to
make a backup copy of the original template before attempting to modify it
for other uses. Note also that the database for problems and cases in this
chapter is contained in spreadsheet C13Data.xls in the Ch13 Bonus
materials folder on the student Premium website as well as in the Instructors
Manual files. Click on the appropriate worksheet tab as noted in the problem (e.g., Prob. 13-1)
to access the data. The Excel templates for control charts used in this chapter are also available in
a separate folder on the Premium website and in the Instructors Resource files.
The numbers for solutions taken from the Excel spreadsheets will
sometimes appear to be slightly different from those produced on a hand
calculator, due to rounding differences and truncated values in the print
routine.
1.

Tri-State Bank is investigating the processing time for loan applications.


Samples were taken for 25 random days from 4 branches. These data
can be found in the worksheet Prob. 13-1.
a. Using Microsoft Excel or similar software with statistical capability,
construct a histogram for these 100 individual readings.
b. Construct a run chart for the sample means.
c. Interpret what the data show. Does the process appear to be in
control?

Chapter 13 - Statistical Process Control

Answer
1.

The following histogram was constructed. (See spreadsheet Prob.1301Chrt.xls for details.)
a)

The distribution has a calculated mean of 12.52. The histogram


shows that the process is somewhat skewed to the right around
the bin with the most frequent values in bin 12.45.

Bin
11.25
11.55
11.85
12.15
12.45
12.75
13.05
13.35
13.65
13.95
13.25

Frequenc
y
0
2
7
16
24
18
18
7
6
1
1

Chapter 13 - Statistical Process Control

b) The run chart of sample means is shown below. It has an extended


string of values from reading 10 to 19, which does not appear to show
random variation.

c) Both the shape of the histogram and the pattern of the sample
means on the run chart suggest abnormal variation. Therefore, it
seems likely that the process is not in control.
2.

Magnum Magnetics makes induction meters used in vending machines


to test the validity of coins. Their specifications require the induction
reading capability of the meters to fall between 0.25 and 0.50 Tesla (T)
units. Quality analysts took 3 random test readings of 30 meters, as
found in the worksheet Prob. 13-2.
a. Using Microsoft Excel or similar software with statistical capability,
construct a histogram for these 90 individual readings.
b. Construct a run chart for the sample means.
c. Interpret what the data show. Does the process appear to be in
control?

Chapter 13 - Statistical Process Control

Answer
2. Results from 30 samples of 3 for Magnum Magnetics measurements
show that the grand mean for all the values is 0.444, which indicates
some off-centering from the assumed nominal value of 0.375 T. (See
spreadsheet Prob13-02Chrt.xls for details.)
a)

The histogram for the data shows:

The histogram appears to be skewed to the right and is not centered


around the mean value. However, all individual values are within
specifications.
b) There seems to be a lot of variability of the sample mean values on
the run chart.

Chapter 13 - Statistical Process Control

c) Due to the pattern of the histogram and the variability shown in the
run chart, it is possible that the process is not in control. Control
charts would have to be constructed to verify this.
3.

J. Phelps Swim Club is trying to calibrate their chlorine pump to ensure that the right
amount of chlorine (1.0 1.5 ppm of free chlorine) is mixed into the water. 30 samples of
3 readings at random times during the week were taken. These data can be found in the
worksheet Prob. 13-03.
a. Compute the mean and range of each sample, calculate control limits, and plot them
on x and R control charts.
b. Does the process appear to be in statistical control? Calculate descriptive statistics that
may help you to determine the answer to this question. What evidence is there for your
conclusion?

Answer
3.

Results from 30 samples of 3 for J. Phelps Swim Club chlorine


measurements were calculated. (See spreadsheet Prob.13-03XR.xls for
details).
a. The control charts are shown below.
b. Interpretation of the control charts show that it is highly likely that
the x chart and the R chart are out of control. On the x chart,

Chapter 13 - Statistical Process Control

samples 2 and 10 are on, or almost on, their control limits. Also,
samples 15 and 17 are more than two standard errors away from the
mean. Finally, sample 30 on the R chart is on the upper control limit.
Assignable causes should be determined and eliminated, and control
limits should be re-calculated.
It should be noted that the process appears to be capable, with all
values within the acceptable limit of 1.0 1.5 based on analysis of the
histogram and descriptive statistics. However, it appears that more
work needs to be done in order to stabilize the process.
For the Center Lines, CL x :

= 1.25; CLR: R = 0.08

Control limits for the x - chart are:


UCL x =

LCL x =

A2 R

+ A2 R = 1.25 + (1.023) 0.08 = 1.33


- A2 R = 1.25 - (1.023) 0.08 = 1.17

For the R-chart:


UCLR = D4 R = (2.574) 0.08 = 0.21
LCLR = D3 R = 0

Chapter 13 - Statistical Process Control

Chapter 13 - Statistical Process Control

4.

Mount Blanc Hospital is working on reducing waiting time in order to give customers
better service in their waiting rooms. Fifty samples of size 5 were taken at random times
from their main waiting room. These data can be found in the worksheet Prob. 13-04.
a. Compute the mean and range of each sample, and control limits, and plot them on x
and R control charts.
b. Does the process appear to be in statistical control? Why or why not?

Answer
4.

Results from 50 samples of 5 for Mount Blanc Hospitals customer


service project were calculated. (See spreadsheet Prob13-04XR.xls for
details.)
a. The control charts are shown below.
b. Analysis shows that the R chart is obviously out of control. On the x
chart, means for samples 6 and 7 are on, or almost on, their control
limits. Assignable causes should be determined and eliminated, and
control limits should be re-calculated.
For the Center Lines, CL x :

= 22.62; CLR: R = 1.94

Control limits for the x - chart are:


UCL x =

A2 R

+ A2 R = 22.62 + (0.577) 1.94 = 23.74

Chapter 13 - Statistical Process Control

LCL x =

- A2

= 22.62 - (0.577) 1.94 = 21.49

For the R-chart:


UCLR = D4 R = (2.114) 1.94 = 4.11
LCLR = D3 R = 0

Chapter 13 - Statistical Process Control

5.

Twenty-five samples of size 4 resulted in statistics of

10

= 30.0 minutes and R = 2.5

minutes for the Excellante Cleaning Companys average time to completely clean a rug.
Compute control limits for x and R charts and estimate the standard deviation of the
process.
Answer
5.
For the Excellante Service Companys center lines, CL x :
CLR : R = 2.5

= 30.0;

Control limits for the x - chart are:


A2 R = 30.0 (0.729) 2.5 = 28.18 to 31.82
For the R-chart: UCLR = D4 R = 2.282 (2.5) = 5.71
x

LCLR = D3 R = 0
Estimated =

/ d2 = 2.5 / 2.059 = 1.21

Note: the d2 value is found in Table B, in the appendix, for a sample


size of 4.

Chapter 13 - Statistical Process Control

6.

Twenty-five samples of size 6 resulted in statistics of

11

= 8.0 and R = 2.0 for the

Quality Service Companys average time to complete an order. Compute control limits
for x and R charts and estimate the standard deviation of the process.
Answer
6.

For the Quality Service Companys center lines, CL x :


R = 2.0

= 8.0; CLR :

Control limits for the x - chart are:


A2 R = 8.0 (0.483) 2.0 = 7.03 to 8.97
For the R-chart: UCLR = D4 R = 2.004(2.0) = 4.01
x

LCLR = D3 R = 0
Estimated =
7.

/ d2 = 2.0 / 2.534 = 0.79

In testing the temperature in an analysis process in Heritage DNA Labs, LLC, containing
both positive and negative values, the data listed in the worksheet Prob. 13-07 were
obtained.
a. Compute the mean, standard deviation and other descriptive statistics for the data.
b. Construct x - and R charts for these data. Determine whether the process is in control.
If not, eliminate any assignable causes and compute revised limits.

Answer

7.

Results from the samples of 50 of size 5 for Heritage DNA Labs, LLC
temperature readings were calculated. (See spreadsheet Prob1307XR.xls for details.)
a. For the 250 individual readings given for Heritage DNA Labs, LLC,
the following descriptive statistics were obtained.

Chapter 13 - Statistical Process Control

Descriptive Statistics
Mean

0.011

Standard Error

0.035

Median

0.055

Mode

0.030

Standard Deviation

0.559

Sample Variance

0.312

Kurtosis

-0.542

Skewness

-0.096

Range

2.600

Minimum

-1.310

Maximum

1.290

Sum

2.710

Count

250

Bin

Frequenc
y

-1.35

-0.95

13

-0.55

32

-0.15

51

0.25

67

0.65

51

1.25

35

1.65

12

Chapter 13 - Statistical Process Control

13

The values appear to be slightly skewed to the left, so the mean is


smaller than the median and the mode.
b) Analysts at Heritage DNA Labs, LLC, calculated the following control
limits. They concluded from the x-bar and R charts that the process is
probably in control, because the points seem to be randomly
distributed in both charts. See spreadsheet Prob13-07XR.xls for more
details.
For the Center Lines, CL x :

= 0.011; CLR: R = 1.372

Control limits for the x - chart are:


x

A2 R = 0.011 0.577 (1.372) = - 0.78 to 0.80

For the R-chart: UCLR = D4 R = 2.11 (1.3718) = 2.89


LCLR = D3 R = 0

Chapter 13 - Statistical Process Control

8.

14

While testing the voltage of a component used in a microcomputer for the Hertz
Company, the data listed in the worksheet Prob. 13-08 were obtained. Construct x - and

Chapter 13 - Statistical Process Control

15

R charts for these data. Determine whether the process is in control. If not, eliminate any
assignable causes and compute revised limits.
Answer
8.

We can see from the initial control charts [labeled as x-bar chart (A)
and R-chart (A)], for the Hertz Company that there are two out-ofcontrol points, one on the x - chart and one on the R - chart. We must
throw out outliers #16, #23, and revise the chart to yield the results
shown in part b), below. (See spreadsheet Prob.13-08XR.xls, tabs for
detailed data on both the original and revised parts.)
For the Center Lines, CL x :

= 402.92; CLR : R = 33.20

Control limits for the x - chart are:


x

A2 R = 402.92 1.023 (33.20) = 368.96 to 436.88

For the R-chart: UCLR = D4 R = 2.574 (33.20) = 85.46


LCLR = D3 R = 0
For the revised x - chart [labeled as x-bar chart (B) and R-chart (B) on
the spreadsheet tabs]:
x

A2 R = 400.29 1.023 (30.96) = 368.62 to 431.96

For the revised R-chart: UCLR = D4 R = 2.574 (30.96) = 79.69


LCLR = D3 R = 0

a) Initial charts

Chapter 13 - Statistical Process Control

b) Revised charts

16

Chapter 13 - Statistical Process Control

9.

17

The data for 25 samples of 4 items each, from the study at Tri-State Bank (Prob. 13-01,
above) was further analyzed in an effort to use it for process control.

Chapter 13 - Statistical Process Control

18

a. Compute the mean and range of each sample, and control limits, and plot them on x and R control charts.
b. Does the process appear to be in statistical control? Why or why not?
Answer
9.

Results from 25 samples of 4 each for Tri-State Banks processing time


for loan calculations were calculated.
a. The control charts were constructed as shown below.
b. The data show that the R chart is obviously out of control at point
10. On the x chart, means for samples 11-19 are all above the mean,
indicating an out-of-control condition. Assignable causes should be
determined and eliminated, and control limits should be re-calculated.
(See spreadsheet Prob13-09XR.xls for details.)
For the Center Lines, CL x :

= 12.52; CLR: R = 1.04

Control limits for the x - chart are:

A2 R

UCL x =

+ A2 R = 12.52 + (0.729) 1.04 = 13.28

LCL x =

- A2 R = 12.52 - (0.729) 1.04 = 11.76

For the R-chart:


UCLR = D4 R = (2.282) 1.04 = 2.37
LCLR = D3 R = 0

Chapter 13 - Statistical Process Control

10.

The data for 30 samples of 3 items each, from the study at Magnum Magnetics (from
Prob. 13-02, above) was further analyzed in an effort to use it for process control.

19

Chapter 13 - Statistical Process Control

20

a. Compute the mean and range of each sample, calculate the control limits, and plot
them on x - and R control charts.
b. Does the process appear to be in statistical control? Why or why not?

Answer
10.

Results from 30 samples of 3 for Magnum Magnetics induction


readings were calculated.
a. The control charts were constructed as shown below.
b. The induction readings on the control charts do not clearly show that
the process is out of control. However, on the x chart, means for
samples 1-4 are on, or almost on, the center line. These and
subsequent points close to the center line, possibly indicate hugging
the center line. Assignable causes, if any, should be determined and
eliminated, and control limits should be re-calculated. (See
spreadsheet Prob13-10XR.xls for details.)
For the Center Lines, CL x :

= 0.378; CLR: R = 0.046

Control limits for the x - chart are:

A2 R

UCL x =

+ A2 R = 0.378 + (1.023) 0.046 = 0.42

LCL x =

- A2 R = 0.378 - (1.023) 0.046 = 0.33

For the R-chart:


UCLR = D4 R = (2.574) 0.046 = 0.12
LCLR = D3 R = 0

Chapter 13 - Statistical Process Control

21

Chapter 13 - Statistical Process Control

11.

22

The data in worksheet Prob. 13-11 list processing time values for 40 samples of size 4
that were taken from Rapid Check Kiters, Inc.s check processing firm over a 20-hour
period.
a. Compute the mean and standard deviation of all 40 samples for the sample data.
b. Calculate the control limits and construct the x - and R charts, using the first 20
samples. Is the process under control at that point?
c. Specifications for the process are 1.065 0.13. If the process is under control, calculate
the capability indexes, Cpu, Cpl, Cp and Cpk using the part of the x - and R charts Excel
template that calculates the process capability. What do the indexes indicate?
d. After calculating the control limits, the last 20 samples were collected. When plotted
using the control limits calculated earlier, does the process appear to be in statistical
control? Why or why not? What should be done if it is not under control?

Answer
11.

The data in worksheet Prob. 13-11 list processing time values for 40
samples of size 4 that were taken from Rapid Check Kiters, Inc.s were
analyzed.
a. The mean and standard deviation for the process (based on data
from all 40 samples shown as descriptive statistics in spreadsheet
Prob13-11AXR.xls) are:
x=

1.070 and = 0.047

b. The control limits (based on the first 20 samples see spreadsheet Prob1311AXR.xls for details) are:
For the Center Lines, CL x :

= 1.069; CLR: R = 0.094

Control limits for the x - chart are:


UCL x =

A2 R

+ A2 R = 1.069 + (0.729) 0.094 = 1.14

Chapter 13 - Statistical Process Control


LCL x =

- A2

= 1.069 - (0.729) 0.094 = 1.00

For the R-chart:


UCLR = D4 R = (2.282) 0.094 = 0.21
LCLR = D3 R = 0

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Chapter 13 - Statistical Process Control

24

The x - and R charts show that the process appears to be under control.
c. The computations for the process capability, taken from the spreadsheet template, show
that the process is minimally capable (see spreadsheet Prob13-07AXR.xls for
details).
Process
Capability
Calculations
Upper
specification
Lower
specification

Six
sigma

0.272

1.205

Cp

1.028

0.925

Cpu
Cpl
Cpk

0.996
1.060
0.996

Capability indexes are Cpu = 0.996, Cpl = 1.060, Cpk = 0.996 and Cp = 1.028. The overall
capability, Cp is satisfactory, since it is greater than 1. The Cpu, which is also the Cpk =
0.996 is unsatisfactory, since it is below 1. The smaller number, with the Cpl = 1.06,
indicates that the process is not centered around the mean. The process should be adjusted
to center it. In addition, steps should be considered to reduce variability in order to
increase capability.

Chapter 13 - Statistical Process Control

25

d. After calculating the control limits, the last 20 samples were plotted
using the same control limits and placed on the control charts, below
(see spreadsheet Prob13-011BXR.xls for details). Note to instructors:
The templates for the x and R charts had to be modified to show the
control limits, based only on the first 30 samples, and the data for the
additional 20 samples were then added to the table and as shown
below.

Chapter 13 - Statistical Process Control

26

Points 21 through 32 on the x -chart show a downward trend and point


29 on the R-chart is out of control. Thus we can conclude that
assignable causes have entered the process and need to be
investigated. Since the control limits were calculated with a stable
process, it is not necessary to recalculate them.
12.

The data in worksheet Prob. 13-12 list electrical resistance values (ohms) for 50 samples
of size 5 that were taken from Babbage Chips, Inc.s computer chip-making process over
a 25-hour period.
a. Compute the mean, standard deviation and other descriptive statistics for the data.
b. Calculate the control limits and construct the x - and R charts, using the first 30
samples. Is the process under control at that point?
c. Specifications for the process are 9.2 3.2 ohms. If the process is under control,
calculate the capability indexes, Cpu, Cpl, Cp and Cpk using the part of the x - and R charts
Excel template that calculates the process capability. What do the indexes indicate?

Chapter 13 - Statistical Process Control

27

d. After calculating the control limits, the last 20 samples were collected. When plotted
using the control limits calculated earlier, does the process appear to be in statistical
control? Why or why not? What should be done if it is not under control?
Note to instructors: The templates for the x and R charts had to be
modified to show the control limits, based only on the first 30 samples,
and the data for the additional 20 samples were then added to the
table and as shown below.
Answer
12.

a) Descriptive statistics for Babbage Chips, Inc., based on all 50


samples, are shown below. The histogram shows the classic bell
curve shape.
Descriptive Statistics Prob. 13-12
Mean
Standard Error
Median
``Mode
Standard Deviation
Sample Variance
Kurtosis
Skewness
Range
Minimum
Maximum
Sum
Count
Conf. Level(95.0%)

9.046
0.070
9.011
9.215
1.103
1.218
-0.323
0.071
5.716
6.341
12.057
2261.440
250.000
0.137

Bin
6.0
6.6
7.2
7.8
8.4
9.0
9.6
10.2
10.8
11.4
12.0
12.6

Frequenc
y
0
3
9
23
36
52
48
44
19
12
3
1

Chapter 13 - Statistical Process Control

28

Histogram
60
Frequency

50
40
Frequency

30
20
10
12.6

12.0

11.4

10.8

10.2

9.6

9.0

8.4

7.8

7.2

6.6

6.0

Bin

b) Results from first 30 samples of 5 for Babbage show that both the x
and R charts are apparently in control. (See spreadsheet Prob1312AXR.xls for details).
For the Center Lines, CL x :

= 9.170; CLR: R = 2.543

Control limits for the x - chart are:

A2 R

UCL x =

+ A2 R = 9.170 + (0.577) 2.543 = 10.64

LCL x =

- A2

= 9.170 - (0.577) 2.543 = 7.70

For the R-chart:


UCLR = D4 R = (2.114) 2.543 = 5.38
LCLR = D3 R = 0

Chapter 13 - Statistical Process Control

29

c) The computations for the process capability, taken from the spreadsheet template, show
that the process is not quite capable (see spreadsheet Prob13-12AXR.xls for
details).

Chapter 13 - Statistical Process Control


Process
Capability
Calculations
Upper
specification
Lower
specification

Six
sigma

6.56

12.4

Cp

0.976

6.0

Cpu
Cpl
Cpk

0.985
0.966
0.966

30

Capability indexes are Cpu = 0.985, Cpl = 0.966, Cpk = 0.966 and Cp = 0.976. All the
indexes are unsatisfactory, since they fall below 1. The smaller number, with the Cpl =
0.966, indicates that the process is not centered around the mean. The process should be
adjusted to center it. In addition, steps should be considered to reduce variability in order
to increase capability.
d) Using the previously calculated control limits to monitor the last 20
samples, there is one unusual occurrence, with seven out of the last
eight samples below the centerline, indicating a probable out-of-control
condition. See spreadsheet Prob13-12BXR.xls for detailed data. Note to
instructors: The templates for the x and R charts had to be modified
to show the control limits, based only on the first 30 samples, and the
data for the additional 20 samples were then added to the table and as
shown below.

Chapter 13 - Statistical Process Control

See file Q8IM13C.DOC - for the next end-of-chapter problem


solutions for Chapter 13.

31

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