1a) Consider a single Sampling Plan with the lot size of 1500, samples

size of 150, and acceptance number of 3. Construct the OC curve. If the

acceptable quality level is 0.05% nonconforming and the limintng quality
leve is 6% non confroming, describe the protection offered by the plan at
these levels.
Lot Size N 1500
Sample Size n 150
Acceptance number c 3
0.05% non conforming means
AQL 99.95% conforming
LTPD 6% non conforming
Function of n,c for OC curve BINOMDIST(c, n, p, TRUE)

P value Formual result

0 1.0000
0.01 0.9353
0.02 0.6472
0.03 0.3384
0.04 0.1458
0.05 0.0548
0.06 0.0186
0.07 0.0058
0.08 0.0017
0.09 0.0005
0.1 0.0001
OC curve

OC Curve
Probability of acceptance of the lot

1.2000

1.0000

0.8000

0.6000 Column B
0.4000

0.2000

0.0000
1 2 3 4 5 6 7 8 9 10 11
Propotion Defective (i.e. 1% defective would be 0.01)

The Protection offered is high as the the Acceptable quality level is

99.95% conforming and limiting quality level is 6% nonconfromeing. So
as per the theory if the AQL >90+% conforming and LTPD <10% non
conforming then it leads the producer for a higher probability of
acceptance and the consumer for a low prorbability of acceptance a lot
with a defect level as high as the LTPD.
The Protection offered is high as the the Acceptable quality level is
99.95% conforming and limiting quality level is 6% nonconfromeing. So
as per the theory if the AQL >90+% conforming and LTPD <10% non
conforming then it leads the producer for a higher probability of
acceptance and the consumer for a low prorbability of acceptance a lot
with a defect level as high as the LTPD.
 Column B

11
 Sample Size
Sample size

Acceptance
Code Letter
Inspection

Inspection

levels and
Problem

Lot Size

General

Actions
Level

AQL
First level Acceptance - 0
First level Rejection - 2
Second level Acceptance - 1
Second level Rejection - 2
Consider Z as defects
In the first 80 samples
if Z=0 The whole lot will be accepted
if Z=1 go for Second sampling
if Z>=2 The whole lot is rejected
In the second 80 samples
First - 80 if Z<= 1 The whole lot will be accepted
a 900 II Normal 0.40% J Second - 80 if Z>= 2 The whole lot is rejected

First level Acceptance -0

First level Rejection - 2
Second level Acceptance - 1
Second level Rejection -2
Consider Z as defects
In the first 315 samples
if Z=0 The whole lot will be accepted
if Z=1 Go for second sampling
if Z>=2 The whole lot is rejected
First - 315 In the second 315 samples
Second - if Z<= 1 The whole lot will be accepted
b 1500 I Tightened 0.15% H 315 if Z>= 2 The whole lot is rejected

First level Acceptance - 5

First level Rejection - 10
Second level Acceptance - 12
Second level Rejection - 16

Consider Z as defects
In the first 20 samples
if Z=5 The whole lot is accepted
if Z=10 Go for second sampling
if Z>=10 The whole lot is rejected
In the second 20 samples
First - 20 if Z<= 12 Accept the whole Lot
c 2000 III Reduced 15.00% L Second - 20 if Z>= 16 Reject the Whole lot
First level Acceptance -0
First level Rejection -2
Second Acceptance -1
Second level Rejection - 2
Consider Z as defects
In the first 315 samples
if Z=0 The whole lot is accepted
if Z=2 Go for second sampling
if Z>=2 Reject the whole lot
In the second 315 samples
First - 315 if Z<= 1 Accept the whole lot
Second - if Z>= 2 Reject the whole lot
315
d 700 II Normal 0.10% J
A B C D E F G H I

LCL Average Length

CL Average length
Average Length

UCL Average
Sample Size

UCL Range

LCL Range
CL Range
Length(

Range
1 50.3 52.93 50.55 48.17 4 8.72 4.13 0
2 48.4 52.93 50.55 48.17 2 8.72 4.13 0
3 48.5 52.93 50.55 48.17 5 8.72 4.13 0
4 49.1 52.93 50.55 48.17 4 8.72 4.13 0
5 52.6 52.93 50.55 48.17 3 8.72 4.13 0
6 46.2 52.93 50.55 48.17 4 8.72 4.13 0 Sample size
7 50.8 52.93 50.55 48.17 3 8.72 4.13 0 Mean of average length
8 52.2 52.93 50.55 48.17 4 8.72 4.13 0 Mean of Range
9 49.5 52.93 50.55 48.17 5 8.72 4.13 0 A2
10 51.7 52.93 50.55 48.17 4 8.72 4.13 0 UCL avg length
11 52.5 52.93 50.55 48.17 5 8.72 4.13 0 LCL avg length
12 47.8 52.93 50.55 48.17 3 8.72 4.13 0 D3
13 49.6 52.93 50.55 48.17 5 8.72 4.13 0 D4
14 50.8 52.93 50.55 48.17 9 8.72 4.13 0 UCL range
15 48.5 52.93 50.55 48.17 4 8.72 4.13 0 LCL range
16 49.3 52.93 50.55 48.17 6 8.72 4.13 0
17 53.3 52.93 50.55 48.17 3 8.72 4.13 0 USL
18 52.1 52.93 50.55 48.17 4 8.72 4.13 0 LSL
19 50.2 52.93 50.55 48.17 5 8.72 4.13 0 d2
As CPK <1 the process
20 51.9 52.93 50.55 48.17 4 8.72 4.13 0 std dev
is not centered and the
21 52.1 52.93 50.55 48.17 2 8.72 4.13 0 CPK
process is not capable
22 49.5 52.93 50.55 48.17 3 8.72 4.13 0 of meeting the
23 50.7 52.93 50.55 48.17 4 8.72 4.13 0 specifications.
24 52.6 52.93 50.55 48.17 5 8.72 4.13 0
25 52.3 52.93 50.55 48.17 6 8.72 4.13 0
26 48.6 52.93 50.55 48.17 5 8.72 4.13 0
27 51 52.93 50.55 48.17 4 8.72 4.13 0
28 52.3 52.93 50.55 48.17 3 8.72 4.13 0
29 50.6 52.93 50.55 48.17 2 8.72 4.13 0
30 51.5 52.93 50.55 48.17 4 8.72 4.13 0

Xbar Chart
54

52
Average
Average Length

50
UCL Ave
48 Length(
CL Avera
46 length
44 LCL Aver
Length
 52
Average

Average Length
50
UCL Ave
48 Length(
CL Avera
46 length
44 LCL Aver
Length
42
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
1 3 5 R Chart
7 9 11 13 15 17 19 21 23 25 27 29
10
Sample Number
9
8
7
6 Range
5
Range

UCL Range
4
CL Range
3
LCL Range
2
1
0
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29
Sample Number
CL
Sample

UCL Avera LCL

Average ge Average
Length length Length Range UCL RangeCL Range
LCL Range
1 50.3 52.83 50.54 48.25 4 8.37 3.97 0
2 48.4 52.83 50.54 48.25 2 8.37 3.97 0 sample size
3 48.5 52.83 50.54 48.25 5 8.37 3.97 0 Mean of average length
4 49.1 52.83 50.54 48.25 4 8.37 3.97 0 Mean of Range
5 52.6 52.83 50.54 48.25 3 8.37 3.97 0 A2
6 46.2 52.83 50.54 48.25 4 8.37 3.97 0 UCL avg length
7 50.8 52.83 50.54 48.25 3 8.37 3.97 0 LCL avg length
8 52.2 52.83 50.54 48.25 4 8.37 3.97 0 D3
9 49.5 52.83 50.54 48.25 5 8.37 3.97 0 D4
10 51.7 52.83 50.54 48.25 4 8.37 3.97 0 UCL range
11 52.5 52.83 50.54 48.25 5 8.37 3.97 0 LCL range
12 47.8 52.83 50.54 48.25 3 8.37 3.97 0
13 49.6 52.83 50.54 48.25 5 8.37 3.97 0 USL
15 48.5 52.83 50.54 48.25 4 8.37 3.97 0 LSL
16 49.3 52.83 50.54 48.25 6 8.37 3.97 0 d2
17 53.3 52.83 50.54 48.25 3 8.37 3.97 0 std dev
18 52.1 52.83 50.54 48.25 4 8.37 3.97 0 CPK
is not centered and the
19 50.2 52.83 50.54 48.25 5 8.37 3.97 0 process is not capable
20 51.9 52.83 50.54 48.25 4 8.37 3.97 0 of meeting the
21 52.1 52.83 50.54 48.25 2 8.37 3.97 0 specifications.
22 49.5 52.83 50.54 48.25 3 8.37 3.97 0
23 50.7 52.83 50.54 48.25 4 8.37 3.97 0
24 52.6 52.83 50.54 48.25 5 8.37 3.97 0
25 52.3 52.83 50.54 48.25 6 8.37 3.97 0
26 48.6 52.83 50.54 48.25 5 8.37 3.97 0
27 51 52.83 50.54 48.25 4 8.37 3.97 0
28 52.3 52.83 50.54 48.25 3 8.37 3.97 0
29 50.6 52.83 50.54 48.25 2 8.37 3.97 0
30 51.5 52.83 50.54 48.25 4 8.37 3.97 0

X bar Chart
54

52

50
Column B
Average Length

UCL Average
48 Length
CL Average
46 length
LCL Average
Length
44

42
2 4 6 8 10 12 14 16 18 20 22 24 26 28
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29
Sample Number

R chart
9
8
7
6
5 Range
Range

4 UCL Range
CL Range
3 LCL Range
2
1
0
2 4 6 8 10 12 14 16 18 20 22 24 26 28
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29
Sample Number

CL
Averag UCL Avera LCL
e Average ge Average
Length Length length Length Range UCL RangeCL Range
LCL Range
50.3 53.04 50.71 48.38 4 8.52 4.04 0
 48.4 53.04 50.71 48.38 2 8.52 4.04 0
48.5 53.04 50.71 48.38 5 8.52 4.04 0 sample size
49.1 53.04 50.71 48.38 4 8.52 4.04 0 Mean of average length
52.6 53.04 50.71 48.38 3 8.52 4.04 0 Mean of Range
50.8 53.04 50.71 48.38 3 8.52 4.04 0 A2
52.2 53.04 50.71 48.38 4 8.52 4.04 0 UCL avg length
49.5 53.04 50.71 48.38 5 8.52 4.04 0 LCL avg length
51.7 53.04 50.71 48.38 4 8.52 4.04 0 D3
52.5 53.04 50.71 48.38 5 8.52 4.04 0 D4
49.6 53.04 50.71 48.38 5 8.52 4.04 0 UCL range
48.5 53.04 50.71 48.38 4 8.52 4.04 0 LCL range
49.3 53.04 50.71 48.38 6 8.52 4.04 0
52.1 53.04 50.71 48.38 4 8.52 4.04 0 USL
50.2 53.04 50.71 48.38 5 8.52 4.04 0 LSL
51.9 53.04 50.71 48.38 4 8.52 4.04 0 d2
52.1 53.04 50.71 48.38 2 8.52 4.04 0 std dev
49.5 53.04 50.71 48.38 3 8.52 4.04 0 CPK
is not centered and the
50.7 53.04 50.71 48.38 4 8.52 4.04 0 process is not capable
52.6 53.04 50.71 48.38 5 8.52 4.04 0 of meeting the
52.3 53.04 50.71 48.38 6 8.52 4.04 0 specifications.
48.6 53.04 50.71 48.38 5 8.52 4.04 0
51 53.04 50.71 48.38 4 8.52 4.04 0
52.3 53.04 50.71 48.38 3 8.52 4.04 0
50.6 53.04 50.71 48.38 2 8.52 4.04 0
51.5 53.04 50.71 48.38 4 8.52 4.04 0

Xbar Chart
54

53

52

51 Average Length
Average length

UCL Average
50 Length
CL Average
49 length
48 LCL Average
Length
47

46
2 4 6 8 10 12 14 16 18 20 22 24 26
1 3 5 7 9 11 13 15 17 19 21 23 25
Sample Number

R Chart
9
8
7
6
5 Range
Range

4 UCL Range
CL Range
3 LCL Range
2
1
0
 9
8
7
6
5 Range

Range
4 UCL Range
CL Range
3 LCL Range
2
1
0
2 4 6 8 10 12 14 16 18 20 22 24 26
1 3 5 7 9 11 13 15 17 19 21 23 25
Sample Number

Comput
Computat Comput ation for
ion for ation for process
first second in
iteration Remarks
iteration Remarks
control Remarks

Daily
Producti
on rate 2000 2000 2000

unit cost
of scrap 1 1 1
rework
cost 0.25 0.25 0.25
USL 53.5 53.5 53.5
LSL 46.5 46.5 46.5
Mean 50.55 50.54 50.71
Std.
Dev. 1.78 1.7 1.74

Comput
ation for
ZUSL 1.657 1.741 1.603
i.e. i.e. i.e.
95.05 95.91 94.84
% is % is % is
within within with in
ZUSL 0.95 range 0.96 range 0.95 range

Comput
ation for
ZLSL 2.275 2.376 2.420
1.16 % 0.89 0.78 %
is out % is is out
of out of of
ZLSL 1.16 range 0.89 range 0.78 range
Reject 6.11 Depicted in %4.98 Depicted in %
5.94 Depicted in %
Scrap
cost 122.2 Depicted in Rs
99.6 Depicted in118.8
Rs Depicted in Rs
rework
cost 30.55 Depicted in Rs
24.9 Depicted in Rs
29.7 Depicted in Rs
Computation
5
50.55
4.13
0.58
52.93
48.17
0
2.11
8.72
0

53.5
46.5
2.33
1.78
0.55

Average Length
UCL Average
Length(
CL Average
length
LCL Average
Length
 Average Length
UCL Average
Length(
CL Average
length
LCL Average
Length

30
29

ange
CL Range
L Range
CL Range
 Number of Samples 25

Area LCL (with LCL (without

Inspected imperfection negative negative
Sl. No (n) old (x) u U average (CL) UCL value) value)
1 150 6 0.040 0.039 0.087 -0.009 0.000
2 100 8 0.080 0.039 0.098 -0.020 0.000
3 200 5 0.025 0.039 0.081 -0.003 0.000
4 150 4 0.027 0.039 0.087 -0.009 0.000
5 250 10 0.040 0.039 0.076 0.002 0.002
6 100 11 0.110 0.039 0.098 -0.020 0.000
7 150 3 0.020 0.039 0.087 -0.009 0.000
8 200 5 0.025 0.039 0.081 -0.003 0.000
9 300 10 0.033 0.039 0.073 0.005 0.005
10 250 10 0.040 0.039 0.076 0.002 0.002
11 100 5 0.050 0.039 0.098 -0.020 0.000
12 200 4 0.020 0.039 0.081 -0.003 0.000
13 250 12 0.048 0.039 0.076 0.002 0.002
14 300 8 0.027 0.039 0.073 0.005 0.005
15 300 12 0.040 0.039 0.073 0.005 0.005
16 200 6 0.030 0.039 0.081 -0.003 0.000
17 150 4 0.027 0.039 0.087 -0.009 0.000
18 200 7 0.035 0.039 0.081 -0.003 0.000
19 150 14 0.093 0.039 0.087 -0.009 0.000
20 100 4 0.040 0.039 0.098 -0.020 0.000
21 100 8 0.080 0.039 0.098 -0.020 0.000
22 200 9 0.045 0.039 0.081 -0.003 0.000
23 300 12 0.040 0.039 0.073 0.005 0.005
24 250 7 0.028 0.039 0.076 0.002 0.002
25 200 5 0.025 0.039 0.081 -0.003 0.000
total 4850 189 1.0677

U chart
0.120

0.100

0.080
u
0.060 U average (CL)
UCL
U

0.040 LCL (without

negative value)
0.020

0.000
2 4 6 8 10 12 14 16 18 20 22 24
1 3 5 7 9 11 13 15 17 19 21 23 25
Sample Number
 negative value)
0.020

0.000
2 4 6 8 10 12 14 16 18 20 22 24
1 3 5 7 9 11 13 15 17 19 21 23 25
Sample Number

Area LCL (with LCL (without

Inspected imperfection negative negative
Sl. No (n) old (x) u U average (CL) UCL value) value)
1 150 6 0.040 0.036 0.082 -0.011 0.000
2 100 8 0.080 0.036 0.092 -0.021 0.000
3 200 5 0.025 0.036 0.076 -0.004 0.000
4 150 4 0.027 0.036 0.082 -0.011 0.000
5 250 10 0.040 0.036 0.071 0.000 0.000
6 150 3 0.020 0.036 0.082 -0.011 0.000
7 200 5 0.025 0.036 0.076 -0.004 0.000
8 300 10 0.033 0.036 0.068 0.003 0.003
9 250 10 0.040 0.036 0.071 0.000 0.000
10 100 5 0.050 0.036 0.092 -0.021 0.000
11 200 4 0.020 0.036 0.076 -0.004 0.000
12 250 12 0.048 0.036 0.071 0.000 0.000
13 300 8 0.027 0.036 0.068 0.003 0.003
14 300 12 0.040 0.036 0.068 0.003 0.003
15 200 6 0.030 0.036 0.076 -0.004 0.000
16 150 4 0.027 0.036 0.082 -0.011 0.000
17 200 7 0.035 0.036 0.076 -0.004 0.000
18 100 4 0.040 0.036 0.092 -0.021 0.000
19 100 8 0.080 0.036 0.092 -0.021 0.000
20 200 9 0.045 0.036 0.076 -0.004 0.000
21 300 12 0.040 0.036 0.068 0.003 0.003
22 250 7 0.028 0.036 0.071 0.000 0.000
23 200 5 0.025 0.036 0.076 -0.004 0.000
total 4600 164 0.8643

U chart
0.100
0.090
0.080
0.070
0.060 u
0.050 U average (CL)
UCL
U

0.040
0.030 LCL (without
0.020 negative value)
0.010
0.000
2 4 6 8 10 12 14 16 18 20 22
1 3 5 7 9 11 13 15 17 19 21 23
Sample Number