QUESTION 1

(a)

Briefly explain:i. Continuous improvement. (2 marks) ii. Zero defects. (2 marks)

(b)

Explain the basic concept of Total Quality Management (TQM). (3 marks)

(c)

Berjaya Corp is a company that produces plastic wheels for toy cars. A new set of machine has been bought for the newly selected material. Now that the production line has been built, a runoff is to be performed. The thickness of all the first lot of wheels were checked for runout. The upper tolerance for the runout is 0.2 mm. What are the mean, standard deviation, and range of the data in Table 1? With an upper specification limit of 0.2 mm, what precentage of the wheels meet the specification? (Instruction: Round the normal distribution value to SIX decimal point and use interpolation method to determine the exact percentage.)

Table 1: Thickness of Lot of Wheels Runout (mm) 0.21 0.13 0.18 0.07 0.02 0.02 0.06 0.04 0.03 0.10 0.25 0.22 0.25 0.04 0.09 0.22 0.04 0.27 0.20 0.11 (18 marks)

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QUESTION 2

(a)

Define the meaning of:i. in control process (2 marks) ii. out of control process

(2marks) (b) A production line supervisor wants to construct a mean ( ) and range (R) chart to monitor quality of their products. He took 15 samples and each sample has four observations as shown in Table 2 .

Table 2 : Observations Quality of Product Sample Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X1 12 9 10 8 13 7 15 14 10 9 14 8 7 10 10 Observation X2 10 10 10 9 14 8 10 13 9 10 8 9 10 10 9 X3 11 8 10 12 15 10 10 8 10 10 9 9 9 8 15 X4 10 14 16 17 8 14 8 16 15 7 14 10 17 14 8

Based on Table 2:Pages 3 of 7

i.

Calculate the mean and range for each sample (4 marks)

ii.

Determine the Center Line, Upper Control Limit and Lower Control Limit for a Mean ( ) and Range (R) control chart. (8 marks)

iii.

Construct the Mean ( ) and Range (R) Chart onto a graph paper (8 marks)

iv.

State whether the process is in control or out of control based on the chart (1 mark)

QUESTION 3 (a) Describe the purpose of non-confirming charts (c-chart) with an appropriate application example. (5 marks) (a) Use data in Table 3, to plot the np-chart and show all the calculations involved.

Table 3: Defective of Product Day 1 2 3 4 5 6 7 8 9 10 11 12 Defectives 10 12 10 11 6 7 12 10 6 11 9 14 Sample Size 100 100 100 100 100 100 100 100 100 100 100 100
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13 14 15 16 17 18 19 20 21 22 23 24 25 TOTAL

16 21 20 12 11 6 10 10 11 11 11 6 9 272

100 100 100 100 100 100 100 100 100 100 100 100 100 2500

(20 marks)

QUESTION 4

a)

State TWO (2) types of attributes of control chart (4 marks)

b)

From data given in Table 4 below, determine:i. U, CL, UCL and LCL (7 marks) ii. Shape of the U chart (12 marks) iii. Conclusion from the trend of the U chart (2 marks)

Table 4: Numbers of Non-Conformities Item Lot Sample Size Total Non-Conformities

UCL LCL

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Number 1 2 3 4 5 6 7 8 9 10 10 10 10 10 10 5 5 5 5 5 45 51 36 48 42 33 27 31 22 25

QUESTION 5

(a)

State TWO (2) disadvantages of acceptance sampling. (4 marks)

(b)

Describe the following sampling plan:i. Single sampling plan (3 marks) ii. Double sampling plan (3 marks) iii. Multiple sampling plan (3 marks)

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(c)

Given the following sampling plan :-

Lot size, N=2000,

Sample size, n=60

Acceptance number, c=2

Use the Cumulative Poisson Distribution Table and construct an Operational Characteristics (OC) Curve with the value of fraction defective from 0.01 to 0.08. (12 marks)

QUESTION 6

(a)

Define the meaning of check sheet. (2 marks)

(b)

State THREE (3) usefulness of check sheet. (6 marks)

(c)

State SEVEN (7) benefits of ISO certification to an organization. (7 marks)

(d)

Brainstorming is a group process technique for eliciting a large number of ideas from a group of people in a relatively short period of time. List a sequence of activities to implement the brainstorming process. (10 marks)

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