Hai Nghiem Homework 1

1. DPMO for the process = [(1500-1477)/1500] *1000000 =15,333, which is beyond the Six Sigma
control (4 defect/1 million opportunities). If the goal of the process is to reach Six Sigma control, then
we can conclude that the process has failed to reach the goal. If we use the SPC process to assess the
performance, we need data over a particular period to reach conclusion.
2. a. Should this inspection position be eliminated?
The cost to inspect/unit: 9/50=0.18
Benefit: 0.04*10=0.4
=> We should keep the inspection position as the cost < benefit.
b. What is the cost to inspect each unit?
$0.18/unit
c. Is there benefit (or loss) from the current inspection process? How much?
The net benefit from the current process is 0.4-0.18=0.22 USD/Unit.
3.a.The specification LSL and USL is (0.99;1.01). The process control limits is (0.993,1.011).
Cpk= min(1.33,0.89) = 0.89
b. The Cpk for the process is shifted to the right and the Cpk <1, meaning the process has problem in
exceeding the uper specification (diameter is too large) and fail to fall within the specification limit.
0.25
0.20
P-defect

0.15

UCL
Pbar

0.10

LCL

0.05
1

9 10

4. a. p-chart for 95 percent

confidence (1.96 standard deviation).
Pbar =0.07
Std=0.06
UCL = 0.19
LCL = 0

Hai Nghiem Homework 1

b. The defective rate for the 2nd and 8th sample is outside the control limit, thus, the company should
investigate these samples to see what happened. For the samples with zero defective items, it would
be worth it to look at those samples too to see factors that could improve the process.
5. a. Cost/unit: 8/20= $0.4
b. The benefit for the inspection: 0.02*25=0.5
=> the benefit from the process: 0.5-0.4=$0.1/unit.
6. Cost/unit: 8/30 = $0.27
Benefit: 3%*10 = $0.3
Because the benefit>cost, the inspector should be hired.
7.a. C-average = 4.3,
UCL = 4.3+2*sqrt(4.3)= 8.45
LCL = 4.3-2*sqrt(4.3) = 0.15
b. The next rolls still have irregularities within the control limits calculated from the previous batch,
thus, the process is under control.
8.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

1010
995
990
1015
1013
994
989
1001
1006
992
996
1019
981
999
1013

Readings (in OHMS)

991
985
986
996
1009
994
1003
1015
1008
1020
1009
998
1019
1005
993
1001
994
1005
992
982
1020
986
996
996
989
1005
1007
1007
1006
979
1006
997
989
996
991
1011
991
989
1003
993
988
984
1002
1005
992

X-bar
993
999
1,004
1,011
1,008
999
996
995
1,002
996
997
1,004
991
991
1,003

25
15
25
22
26

X-bar
A2
R-bar
D3
D4

Range (Ri)
999
0.73
22
0
2.28

UCL(X)
LCL(X)
UCL( R)
LCL( R)

1,015
983
50
0
11
38
15
18
28
17
28
22
15
21

Hai Nghiem Homework 1

40
35
30
25
20
15
10
5
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
X chart

R chart

1,015
1,010
1,005
1,000
995
990
985
980
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Comment: the Xbar and R chart for the process shows that the observed values fall within the control
level in both the sample means (X bar) and sample ranges (R chart). In other words, the process is in
control.
9.a. The information can be expressed as follows:

Hai Nghiem Homework 1

AQL: 3%
: 5%
LTPD: 10%
: 10%
=> LPTD/AQL= 3.33 => c= 5 => n/AQL=2.613
=> n= 87.1.
The sample size should be tested is 87 parts.
b. The number of defect in 87 items must be equal to or lower than 5.
10.

Date
1-Dec
2-Dec
3-Dec
4-Dec
5-Dec
6-Dec
7-Dec
8-Dec
9-Dec
10-Dec
Total

Number of
Unsatisfactoy
Meals
74
42
64
80
40
50
65
70
40
75
600
P mean = 0.06
Se = 0.075
UCL= 0.075
LCL = 0.045

Sample
Size
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
10000

Pi
0.074
0.042
0.064
0.08
0.04
0.05
0.065
0.07
0.04
0.075
0.06
(mean)

Hai Nghiem Homework 1

0.09
0.08
0.07
0.06
0.05
0.04
0.03
0.02
0.01
0

Pi
UCL
LCL

10

Comment: The result of the survey shows that the percentage of unsatisfactory meals varies a lot.
There were two days, 4 and 10 in which the number of satisfactory meals is out of the intervals.
Special inpection should be made to these days to see what happened and what can be done. Mean
while, it should also be understood why the 2nd, 5th and 9th day have very low level of unsatisfactory
meals.
11. a. We have AQL of 0.15 and LPTD of 0.4. To implement the test plan, we need to decide the size
of the test sample (n) and the acceptance level (c) which we use to decide if the sample passes or
not.
In order to calculate n and c, the chip department must decide the level of which they accept the risk
of rejecting a good batch (alpha) and the assembly department must decide the level they accept the
risk of accepting a bad batch (beta).
b. Sampling plan is a plan to test a single sample to decide if the sample meet the specification. We
need to decide the sample size to be tested and the maximum number of defects acceptable at certain
level of risk.
12.
0.02
0.01
0.01
0.01
0.01
Mont
h

Crime Incidence

Sample
Size

0.01
0
0
0

Jan

1000

Crime
Rate
0.007

Feb

1000

0.009

Crime Rate
UCL
LCL
P bar

Hai Nghiem Homework 1

Mar

1000

0.007

Apr

1000

0.007

May

1000

0.007

Jun

1000

0.009

Jul

1000

0.007

Aug

10

1000

0.01

Sep

1000

0.008

Oct

11

1000

0.011

Nov

10

1000

0.01

Dec

1000

0.008

JAn

10

1000

0.01

Feb

12

1000

0.012

MAr

11

1000

0.011

Jan-Dec:
0.008

P mean
Se

0.003

UCL

0.014

LCL

0.003

Comment: The crime rate seems to be under control within the intervals of (0.003 and 0.014).
However, in the last 3 months (Jan-Mar), the rate is increasing and is above the mean level for the
previous year, which should be a concern over the trend.
0.04
0.03
0.03

Crime Rate

0.02

UCL
LCL

0.02

P bar

0.01
0.01
0

13.
Locatio
n
1
2
3
4
5
6

No of
crimes
14
3
19
18
14
28

Sample
Size
1000
1000
1000
1000
1000
1000

Crime
Rate
0.014
0.003
0.019
0.018
0.014
0.028

Hai Nghiem Homework 1

7
8
9
10
11
12
13
14
15
16
17
18
19
20

10
18
12
3
20
15
12
14
10
30
4
20
6
30
Mean
P
Se
UCL
LCL

1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000

0.01
0.018
0.012
0.003
0.02
0.015
0.012
0.014
0.01
0.03
0.004
0.02
0.006
0.03

0.015
0.004
0.023
0.007

Based on the crime rate chart above, the city should allocate more crime protection effort to the areas
with highest potential for crimes, in this case, they are 6, 16 and 20. These areas have the crime rate
that are out of control level. The areas in which the rate is low can have lower protection. They are 2,
10, 17 and 19.
14.
Sample Number

Observation
1

0.486

0.499

0.499

0.506

0.496

4
5

Xbar

Range

0.493

0.511

0.481

0.494

0.03

0.516

0.494

0.529

0.5088

0.035

0.5

0.515

0.488

0.521

0.504

0.033

0.495

0.506

0.483

0.487

0.489

0.492

0.023

0.472

0.502

0.526

0.469

0.481

0.49

0.057

0.473

0.495

0.507

0.493

0.506

0.4948

0.034

0.495

0.512

0.49

0.471

0.504

0.4944

0.041

0.525

0.501

0.498

0.474

0.485

0.4966

0.051

0.497

0.501

0.517

0.506

0.516

0.5074

0.02

10

0.495

0.505

0.516

0.511

0.497

0.5048

0.021

11

0.495

0.482

0.468

0.492

0.492

0.4858

0.027

12

0.483

0.459

0.526

0.506

0.522

0.4992

0.067

13

0.521

0.512

0.493

0.525

0.51

0.5122

0.032

14

0.487

0.521

0.507

0.501

0.5

0.5032

0.034

15

0.493

0.516

0.499

0.511

0.513

0.5064

0.023

16

0.473

0.506

0.479

0.48

0.523

0.4922

0.05

17

0.477

0.485

0.513

0.484

0.496

0.491

0.036

18

0.04

0.515

0.493

0.493

0.485

0.475

0.4922

19

0.511

0.536

0.486

0.497

0.491

0.5042

0.05

20

0.509

0.49

0.47

0.504

0.512

0.497

0.042

0.49851

0.0373

Mean

Hai Nghiem Homework 1

X-bar

0.49851

UCL(X)

0.520144

0.58

LCL (X)

0.476876

0.0373

UCL( R)

0.078703

D3

LCL ( R)

D4

2.11

A2
R mean

0.53
0.52
0.51
0.5
0.49
0.48

Xbar
UCL (X)
Xbar
LCL(X)

0.47
0.46
0.45

0.09
0.08
0.07
0.06

Range

0.05

UCL( R)

0.04

Mean R

0.03

LCL ( R)

0.02
0.01
0

Comment: The length dimension is within control level in terms of mean and range. We could say
that the process is in control.
15. Cpk = min([(4.001-3.997)/(3*0.002)] and [(4.003-4.001)/(3*0.002)])

Hai Nghiem Homework 1

= min (0.67,0.33) = 0.33
The Cpk of the machine is lower than 1, meaning the machine is operating out of the 3 intervals and
is not capable under the six sigma theory => C-Spec shouldnt use this machine.
16. a. Supposed that the process currently has mean of 100, the Cpk of the process is:
Cpk = min [10/(3*4) and 10/(3*4)] = 0.83 <1
Currently, the process does operate within 3, thus, it is not capable.
b. New Cpk = min [(92-90)/12 and (110-92)/12] = min (0.17 & 1.5) = 0.17.
c. The process is shifted to the left. With 0.17 Cpk, the mean of the process is 0.5 from the lower
specification level. With this, using norm.dist function, we will have nearly 31% of the products
defective.