Quality Control Methods: Fill-in-the-Blank Questions

Quality Control Methods
Chapter 16
Fill-in-the-Blank Questions
Section 16.1
1. __________ are now used extensively in industry as diagnostic techniques for monitoring
production processes to identify instability and unusual circumstances.
ANSWER: Control charts
2. Sources of variation that may have a pernicious impact on the quality of items produced by some
process, such as contaminated material, are referred to as __________ in the quality control
literature.
ANSWER: assignable causes
3. In addition to the plotted points themselves (e.g., sample means or sample proportions), a control
chart has a __________ and two__________.
ANSWER: center line, control limits
4. When an out-of-control process produces a point inside the control limits, a type __________
error has occurred.
ANSWER: II
5. When an in-control process yields a point outside the control limits (an out-of-control signal), a
type __________ error has occurred.
ANSWER: I
6. If the points on a control chart all lie between the two central limits, the process is deemed to
__________.
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CHAPTER SIXTEEN
ANSWER: in control
Section 16.2
7. Any point outside the lower control limit (LCL) and/or the upper control limit (UCL) of a 3-sigma
x chart suggests that the process may have been __________ at that time, so a search for
__________ should be initiated.
ANSWER: out-of-control, assignable courses
8. An x control chart is constructed using 25 samples of size 3 each, when the process is in-control
and the random variable of interest is normally distributed with a mean of 20 and standard
deviation of 1.732. Then, the 3 standard deviation control limits are LCL = __________ and UCL
=__________.
ANSWER: 17, 23
9. The two control limit for 3 sigma x chart have been calculated. If the variable of interest is
normally distributed, and 3 is replaced by 3.09 in the control limits formulas, then probability of
Type I error ( a ) __________, but for any fixed n and s , probability of Type II error ( b ) will
__________.
ANSWER: decreases, increase
10. The two control limits for 3=sigma x chart have been calculated. If the variable of interest is
normally distributed, and 3 is replaced by 2.5 in the control limits formulas, then probability of
Type I error ( a ) __________, but for fixed n and s , probability of Type II error ( b ) will
__________.
ANSWER: increases, decrease
11. An x control chart is based on control limits m �2.5s / n . When the process is in control, then
the probability that a point falls outside the limits is __________.
ANSWER: .0124
12. An x control chart is based on control limits m0 �2.88s / n . When the process is in control,
then the average run length (ARL) is __________.
ANSWER: 250
Section 16.3
13. The sample variance S 2 is an unbiased estimator of the population variance s 2 ; that is,
__________ = __________.
ANSWER: E ( S ) , s
2 2
14. For a sample of size 5, the tabulated value of a = .94. If the population standard deviation
s = 2.50, then the standard deviation of the sample standard deviation S is s s = __________,
rounded to 3 decimal places.
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ANSWER: .853
15. The 3-sigma lower control limit (LCL) for an S chart is given by LCL = s - 3s 1 - an2 / an where
the values of an for n=3, ….., 8 are tabulated in your text. This expression for LCL will be
negative if n �__________, in which case it is customary to use LCL = __________.
ANSWER: 5, 0
16. Suppose there are 25 samples obtained at equally spaced time points, and n=5 observations in each
sample. If the sum of the 25 sample standard deviations is 50, then the center line of the S chart
will be at height equals to __________.
ANSWER: 2
sample. If the sum of the 24 samples ranges is 108, then the center line of the R chart will be at
height equals to __________.
ANSWER: 4.5
18. The 3-sigma lower control limit (LCL) for an R chart is given by LCL = r - 3cn r / bn where the
values of bn and cn for n=3,…..,8 are tabulated in your text. This expression for LCL will be
negative if n �__________, in which case it is customary to use LCL = __________.
ANSWER: 6, 0
Section 16.4
19. The term __________ data is used in quality control to describe situations such as each item
produced conforms to specifications or does not, or a single item (e.g., one automobile) may have
one or more defects, and the number of defects is determined.
ANSWER: attribute
20. The c control chart for the number of defectives in a single item (e.g., one automobile) or a group
of items (e.g., blemishes on a set of four tires) is based on the __________ probability distribution.
ANSWER: Poisson
21. Suppose that 25 samples, each of size 100, were selected from what is believed to be an in-control
process, and that Spˆ i = 1.8, where pˆ i is the fraction of defective items in sample i. The p chart for
the fraction of defective items has its center line at height equals to __________.
ANSWER: .072
22. If Y is a Poisson random variable with parameter q , then E(Y) = __________, V(Y) =
__________, and also has approximately a __________ distribution when q is large
( q �10 will suffice for most purposes ) .
ANSWER: q ,q , normal
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CHAPTER SIXTEEN
23. The p control chart for the fraction of defective items produced is based on the __________
probability distribution.
ANSWER: binomial
n
24. If Y1 , Y2 ,.....Yn are independent Poisson variables with common parameter q , then �Y has also a
i =1
i
Poisson distribution with parameter l = __________, where l denotes the expected number of
defects per unit.
ANSWER: nq
25. The use of 3-sigma control limits is presumed to result in P(statistic <LCL �__________, when
the process is in control.
ANSWER: .0013
26. The 3-sigma control limits of the p chart for the fraction of defective items in a process believed to
be in control are LCL = .0125 and UCL = .1425. If the smallest and largest values of pˆ, the
fraction of defective items, are .0062 and .1685 respectively, then the process is __________.
ANSWER: out of control
Section 16.5
27. There are two equivalent versions of a cumulative sum procedure for a process mean, one
__________ and the __________.
ANSWER: graphical, computational
28. At time r, a process is judged out of control if any of the cumulative sum plotted values
( 1, Si ) , ( 2, S 2 ) ,....., ( r , Sr ) lies outside the __________; either above the upper arm or below the
lower arm.
ANSWER: V-mask
29. If the size of a shift in a process mean m is .40, then the customarily value of the slope of the
lower arm of the V-mask is __________.
ANSWER: .20
30. The __________ is a chart developed by Kenneth Kemp that can be used to determine values of h
and n that achieves a specified ARL (average run length).
ANSWER: kemp nomogram
56
Section 16.6
31. The behavior of a sampling plan can be nicely summarized by graphing P(A); the probability that
the lot is accepted, as a function of p; the proportion of defective items in the lot. Such a graph is
called the __________ for the plan.
ANSWER: operating characteristic curve
32. Let p denote the proportion of defective items in the lot, and P(A) denote the probability that the
lot is accepted. Let us designate two different values of p, one for which P(A) is a specified value
close to 1 and the other for which P(A) is a specified value near 0. These tow values of
p - say pi and p2 - are often called the __________, denoted AQL, and the __________, denoted
by LTPD.
ANSWER: acceptance quality level, lot tolerance percent defective
33. In a double-sampling plan, it is customary to terminate inspection of the second sample if the
number of defectives is sufficient to justify rejection before all items have been examined. This is
referred to as __________ in the second sample.
ANSWER: curtailment
34. One important characteristic of a sampling plan with rectifying inspection is the __________,
denoted by AOQ.
ANSWER: average outgoing quality
35. Under curtailment in a double-sampling plan, it can be shown that the expected number of items
inspected in a __________ is smaller than the number of items examined in a __________ when
the operating characteristic (OC) curves of the two plans are close to be identical.
ANSWER: double-sampling plan, single-sampling plan
36. The average outgoing quality equals 0 when the proportion of defective items in the lot, p, is either
__________ or __________.
ANSWER: 0, 1
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CHAPTER SIXTEEN
Multiple-Choice Questions
Section 16.1
37. Which of the following statements are not true?
A. Raising quality levels can lead to decreased costs, a greater degree of consumer satisfaction,
and thus increased profitability.
B. Control Charting is now used extensively in industry as a diagnostic technique for monitoring
production processes to identify instability and unusual circumstances.
C. The basis for most of control charts lies in our work concerning probability distributions of
various statistics such as the sample mean x and sample proportion pˆ = X / n.
D. All of the above statements are true.
E. None of the above statements are true.
ANSWER: D
A. Control charts and acceptance sampling plans were first developed in the 1960’s and 1970’s.
B. Statisticians and engineers have recently introduced many statistical methods for identifying
types and levels of production inputs that will ensure high-quality output.
C. There is a large body of material known as “Taguchi methods”, named after Japanese
engineer/statistician G. Taguchi.
ANSWER: A
39. Which of the following are not examples of assignable causes of variation?
A. Contaminated material
B. Incorrect machine settings
C. Environmental factors
D. Unusual machine tools wear
E. All of the above
ANSWER: C
40. Which of the following statements are true?
A. We might think of “natural random variation” as uncontrollable background noise.

B. Control charts provide a mechanism for recognizing situations where assignable causes may
be adversely affecting product quality.
C. Once a control chart indicates an out-of-control situation, an investigation can be launched to
identify causes and take corrective action.
D. A basic element of control charting is that samples have been selected from the process of
interest at a sequence of time points.
E. All of the above statements are true.
ANSWER: E
58
A. The basis for the choice of a center line for a control chart is sometimes a target value or
design specification, for example a desired value of the bearing diameter.
B. An “in-control” process is a process that “meets design specifications or tolerance”.
C. An in-control process is simply one whose behavior with respect to variation is stable over
time, showing indications of unusual extraneous causes.
D. If the points on a control chart all lie between the two control limits, the process is deemed to
be in control.
ANSWER: B
A. An in-control process is simply one that is operating in a stable fashion, reflecting only
natural random variation.
B. An out-of-control “signal” occurs whenever a plotted point falls outside the two control
limits.
C. There is a strong analogy between the logic of control charting and hypothesis testing. The
null hypothesis here is that the process is out-of-control.
D. The two control limits are designed so that an in-control process generates very few false
alarms, whereas a process not in control quickly gives rise to a point outside the limits.
ANSWER: C
Section 16.2
A. To construct an X chart, there are two different commonly used methods for estimating the
unknown process standard deviation s ; one based on the k sample standard deviations and
the other on the k sample ranges.
B. In the case of a normal population distribution, the estimator of the unknown process standard
deviation s based on sample standard deviations S is more efficient than that based on the
sample range.
C. The sample standard deviation S is an unbiased estimator of the population standard deviation
s ; that is, E(S)= s .
ANSWER: C
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CHAPTER SIXTEEN
A. One important use of control charts is to see whether some measure of location of the
variable’s distribution remains stable over time.
B. It is highly unlikely that for an in-control process, the sample mean will fall within 3 standard
( )
deviations 3s / n of the process mean m .
C. The use of control charts based on 3 standard deviation limits is traditional, but tradition is
certainly not inviolable.
ANSWER: B
45. Assume that for an in-control process, the random variable of interest X has a normal distribution
with mean value m and standard deviation s . If X denotes the sample mean for a random
sample of size n selected at a particular time, then
A. E( X ) = m
B. s x = s / n
C. X has a normal distribution.
D. All of the above are true.
E. None of the above are true.
ANSWER: D
46. Suppose that at each of the time points 1,2,3,….., a sample of size n is selected at random from a
normal distribution with known mean m and standard deviation s . In order to construct a 3-
sigma X chart, we need to
A. determine x1 , x2 , x3 ,.....; calculated values of the corresponding sample means.

B. plot xi ' s over time; that is, plot the points ( 1, x1 ) , ( 1, x2 ) , ( 1, x3 ) ,..... and so on.
C. Draw horizontal lines across the plot as m �3s / n .
D. All of the above are needed.
E. Only A and B are needed.
ANSWER: D
A. Generally speaking, a control chart will be effective if it gives very few out-of-control signals
when the process is I control, but shows a point outside the control limits almost as soon as
the process goes out of control.
B. One assessment of a control chart’s effectiveness is based on the notion of “error
probabilities” a , and b .
C. The use of a 3-sigma limits for an X chart makes it highly unlikely that an out-of-control
signal will result from an in-control process.
D. One assessment of a control chart’s effectiveness involves the average run length (ARL)
needed to observe an out-of-control signal.
60
ANSWER: E
48. The inability of X charts with 3-sigma limits to quickly detect small shifts in the process mean
has prompted investigators to develop procedures that provide improved behavior in this respect.
Which of the following conditions need to be satisfied for an appropriated intervention to take
corrective action?
A. Two out of three successive points fall outside 2-sigma limits on the same side of the center
line.
B. Four out of five successive points fall outside 1-sigma limits on the same side of the center
line.
C. Eight successive points fall on the same side of the center line.
D. All of the above.
E. None of the above.
ANSWER: D
Section 16.3
A. It is important to ensure that a process is under control with respect to location (equivalently,
central tendency) as well as variation.
B. Most practitioners recommend that control of a process be established on variation prior to
constructing an X chart or any other chart for controlling location.
C. Charts for variation are based on the sample standard deviation S and also based on the
sample range R.
D. Charts for variation that are based on the sample standard deviation S are generally preferred
over charts that are based on the sample range R because the standard deviation gives a more
efficient assessment of variation than does the range.
ANSWER: E
50. Suppose that k independently selected samples are available, each one consisting of n observations
on a normally distributed variable. Denote the sample standard deviations by s1 , s2 ,....., sk . The
values s1 , s2 ,....., sk are plotted in sequence on an S chart. The center line of the chart will be at
height equals to the
A. average of the values s1 , s2 ,....., sk .

B. range of the values s1 , s2 ,....., sk .
C. standard deviation of the values s1 , s2 ,....., sk .
D. first quartile of the values s1 , s2 ,....., sk .
E. third quartile of the values s1 , s2 ,....., sk .
ANSWER: A
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CHAPTER SIXTEEN
51. Suppose there are 10 sample obtained at equally spaced time points, and n=4 observations in each
sample. If the sum of the 20 sample standard deviations is 42, and that the tabulated value of a4
is .921, then the 3-sigma control limits LCL and UCL for an S control chart are respectively
A. 1.062 and 3.138

B. 3.138 and 4.765
C. 0.0 and 4.765
D. -.354 and 4.554
E. -.565 and 4.765
ANSWER: C
sample. If the sum of the 28 sample ranges is 98, and that the tabulated values of b7 and c7 are
2.706 and .833, respectively, then the 3-sigma control limits LCL and UCL for an R control chart
are respectively
A. 0.0 and 6.73

B. .27 and 6.73
C. -30.61 and 37.61
D. 0.0 and 37.61
E. None of the above answers are correct.
ANSWER: B
53. Which of the following statements are not correct?
A. For a 3-sigma X chart, where the process mean m and standard deviation s are known, the
probability that a point on the chart falls above the UCL is .013, as is the probability that the
point falls below the LCL.
B. For a 3-sigma S chart, P ( Si > UCL ) = P ( Si < LCL ) = .0013
C. For a 3-sigma R chart, P ( Ri > UCL ) = P ( Ri < LCL ) = .0013.
D. Only B and C are not correct.
E. Only A and C are not correct.
ANSWER: D
Section 16.4
54. Consider a sample of n items obtained at a particular time, and let X be the number of defectives
and pˆ = X / n. Which of the following statements are not true?
A. E(X) = np
B. V(X) = p(1-p)
C. E ( pˆ ) = p
D. V ( pˆ ) = p ( 1 - p ) / n
E. If np �10 and n ( 1 - p ) �10, pˆ has approximately a normal distribution.
62
ANSWER: B
55. Suppose that 25 samples, each of size 200, we selected from what is believed to be an in-control
process, and that Spˆ i is the fraction of defective items in sample i. The 3-sigma control limits,
LCL and UCL, of the p chart for the fraction of defective items are respectively
A. .0236 and .244

B. -.0462 and .0942
C. 0 and .0564
D. 0 and .0942
E. -.0084 and .0564
ANSWER: C
56. Assume that the total number of defects in 50 samples are 450. Which of the following statements
are not true regarding the c chart for the number of defectives?
A. The center line of the chart is at height 9

B. The lower control limit (LCL) is 0
C. The upper control limit (UCL) is 18
D. All of the above statements are true
E. None of the above statements are true
ANSWER: D
A. The p control chart for the fraction of items not conforming to specifications is based on the
binomial probability distribution.
B. The c control chart for the number of defectives is based on the Poisson probability
distribution.
C. If the random variable X has a binomial distribution with parameters n and p, then when p is
small the transformation Y = h ( X ) = sin
-1
( X /n ) is recommended and that the points
y1 , y2 ,....., yn should be used to construct the p chart.
D. If the random variable X has a Poisson distribution with parameter l , and l is small, then the
transformation Y = h ( X ) = 2 X is recommended and that the points y1 , y2 ,..... should be
used to construct the c chart.
E. All of the above statements are correct
ANSWER: E
Section 16.5
A. The CUSUM procedures discussed in your text are used for controlling process location.
B. There are CUSUM procedures for controlling process variation.
C. There are CUSUM procedures for attribute data.
D. None of the above statements are true.
ANSWER: E
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CHAPTER SIXTEEN
A. A defect on the traditional X chart is its inability to detect a relatively small change in a
process mean.
B. Whether a process is judged out of control at a particular time depends only on the sample at
that time, and not on the past history of the process.
C. The computational version of a cumulative sum (CUSUM) procedure is used almost
exclusively in practice, but the logic behind the procedure is most easily grasped by first
considering the graphical form.
ANSWER: D
A. A particular V-mask is determined by specifying the “lead distance” d and “half angle” q , or
equivalently, by specifying d and the length h of the vertical line segment from 0 to the lower
(or to the upper) arm of the mask.
B. One method for deciding which V-mask to use involves specifying the size of a shift in the
process mean that is of particular concern to an investigator, then the parameters of the mask
are chosen to give desired values of a and b ; the false-alarm probability and the probability
of not detecting the specified shift, respectively.
C. One method for deciding which V-mask to use involves selecting the mask that yields
specified values of the ARL (average run length) both for an in-control process and for a
process in which the mean has shifted by a designated amount.
ANSWER: D
A. If we let D denote the size of a shift in a process mean m that is to be quickly detected using
a CUSUM procedure, then it is common practice to let k = 2D, where k denotes the slope of
the lower arm of the V-mask.
B. A quality control practitioner may specify a desired value of an ARL (average run length)
when the process is in control ( m = m0 ) .
C. A quality control practitioner may specify a desire value of an ARL (average run length) when
the process is out of control because the mean has shifted by D ( m = m0 + D or m = m0 - D ) .
ANSWER: A
64
Section 16.6
A. Until quite recently, control chart procedures and acceptance sampling techniques were
regarded by practitioners as equally important parts of quality control methodology, but this is
no longer the case.
B. Acceptance sampling deals with what has already been produced and thus does not provide
for any direct control over process quality.
C. The most straightforward type of acceptance sampling plan involves selecting a single
random sample of size n and then rejecting the lot if the number of defectives in the sample
exceeds a specified critical value c.
D. We want an operating characteristic (OC) curve that is higher for very small p(proportion of
defective items) and lower for larger p. This can be achieved by increasing the sample size n
and the specified critical value c.
ANSWER: E
63. In acceptance sampling, the risk of accepting a poor quality lot is considered a
A. Type I error.
B. consumer’s risk.
C. producer’s risk.
D. bad luck lot.
E. None of the above.
ANSWER: B
64. Let the random variable X denote the number of defective items in the lot, A denote the event that
the lot is accepted, and p denote the proportion of defective items in the lot. Which of the
following statements is not true?
A. If the sample size n is large relative to the lot size N, then the probability of accepting the lot,
P(A), is calculated using the hypergeometric distribution.
B. When the sample size n is small relative to the lot size N (the rule of thumb suggested in your
text was n �.05 N ), then the probability of accepting the , P(A), is calculated using the
binomial distribution.
C. If the probability of accepting the lot, P(A), is large only when p is small (this, of course,
depends on the specified critical value c), then the Poisson approximation to the binomial
distribution is justified.
D. The larger value of p, the larger the probability P(A) of accepting the lot.
ANSWER: D
65. In acceptance sampling, the risk of rejecting a good quality lot is considered a
A. Type II error
B. consumer’s risk
C. producer’s risk
D. bad luck lot
E. None of the above
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CHAPTER SIXTEEN
ANSWER: C
66. Consider a double-sampling plan with n1 = 80, n2 = 80, c1 = 2, r1 = 5, and c2 = 6. Which of the
following equalities are not correct if the lot will be accepted?
A. x1 = 5 and x2 = 0,1, or 2
B. x1 = 4 and x2 = 0,1, or 2
C. x1 = 3 and x2 = 0,1, or 2
D. x1 = 0,1, or 2
E. None of the above are correct
ANSWER: A
A. One standard method for designing a double-sampling plan involves specifying values
p1 and p2 along with corresponding acceptance probabilities 1 - a and b , then find a plan that
satisfies these conditions.
B. The average outgoing quality (AOQ) is the short-run proportion of defective items among
those sent on before the sampling plan is employed.
C. Because the average outgoing quality AOQ = 0 when either p = 0 or p = 1, it follows that
there is a value of p between 0 and 1 for which AOQ is a maximum.
D. The maximum value of the average outgoing quality (AOQ) is called the average outgoing
quality limit (AOQL).
E. It is common practice to select a sampling plan that has a specified average outgoing quality
limit (AOQL) and, in addition, minimum average total number inspected (ATI) at a particular
quality level p.
ANSWER: B
66
Applied and Computational Questions
Section 16.1
68. A control chart for thickness of rolled-steel sheets is based on an upper control limit of .0525 inch
and a lower limit of .0475 inch. The first ten values of the quality statistic (in this case X , the
sample mean thickness of n =5 sample sheets) are .0508, .0495, .0504, .0503, .0514, .0500, .
0487, .0502, .0507, and .0485. Comment on the behavior of this control chart.
ANSWER:
All ten values of the quality statistic are between the two control limits, so no out-of-control signal
is generated.
69. A control chart for thickness of rolled-steel sheets is based on an upper control limit of .0525 inch
and a lower limit of .0475inch. Suppose the ten most recent values of the quality statistic are .
0493, .0485, .0490, .0503, .0492, .0486, .0495, .0494, .0493, and .0488. Comment on the behavior
of this control chart.
ANSWER:
All ten values are between the two control limits. However, -it is readily verified that all but one
plotted point fall below the center line( at height .04975). Thus even though no single point
generates an out-of-control signal, taken together, the observed values do suggest that there may
be a decrease in the average value of the quality statistic. Such a “small” change is more easily
detected by a CUSUM procedure than an ordinary chart.
70. Suppose a control chart is constructed so that the probability of a point falling outside the control
limits when the process is actually in control is .005.
a. What is the probability that ten successive points (based on independently selected samples)
will be within the control limits?
b. What is the probability that 25 successive points will all lie within the control limits?
c. What is the smallest number of successive points plotted for which the probability of
observing at least one outside the control limits exceeds .10?
ANSWER:
a. P (10 successive points inside the limits) = P(1st inside) x P(2nd inside) x…x P(10th inside) =
(.995)10 = .9511.
P (25 successive points inside the limits) = (.995) = .8822.
25
b.
c. (.995)52 = .7705, but (.995)53 = .7667 , so for 53 successive points the probability that at least
one will fall outside the control limits when the process is in control is 1-.7667 = .2333 > .10.
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CHAPTER SIXTEEN
Section 16.2
71. In the case of known m and s , what control limits are necessary for the probability of a single
point being outside the limits for an in-control process to be .003?
ANSWER:
For a standard normal random variable Z, P ( -c �Z �c ) = .997 . This implies that
.003
F ( c ) = P ( Z �c ) = .997 + = .9985. The table of “standard normal curve areas” available in
2
your text then gives c = 2.96. The appropriate control limits are therefore m �2.96s .
72. Consider a 3-sigma control chart with center line at m0 and based on n = 5. Assuming normality,
calculate the probability that a single point will fall outside the control limits when the actual
process mean is
a. m0 + .5s
b. m0 - s
c. m0 + 2s
ANSWER:
a. P (point falls outside the limits when m = m0 + .5s )
� 3s 3s �
= 1 - P �m0 - < X < m0 + when m = m0 + .5s �
� n n �
(
= 1 - P -3 - .5 n < Z < 3 - .5 n )
= 1 - P( -4.12 < Z < 1.882) = 1 - .9699 = .0301.
� 3s 3s �
b. 1 - P �m0 - < X < m0 + when m = m0 - s �
� n n �
( )
= 1 - P -3 + n < Z < 3 + n = 1 - P (-.76 < Z < 5.24) = .2236
( )
c. 1 - P -3 - 2 n < Z < 3 - 2 n = 1 - P(-7.47 < Z < -1.47) = .6808
73. The accompanying table gives sample means and standard deviations, each based on n = 6
observations of the refractive index of fiber-optic cable. Calculate the control limits for an X
chart based on the sample standard deviations given, and comment on the behavior of the chart.
[Hint: �xi = 2317.07 and �si = 30.34. ]
Day x s Day x s
1 96.43 0.75 13 96.63 1.48
2 97.06 1.34 14 96.50 080
3 98.34 1.60 15 97.22 1.42
4 96.42 1.22 16 96.55 1.65
5 95.99 1.18 17 96.01 1.58
6 96.52 1.27 18 95.39 0.98
7 96.08 1.16 19 96.58 1.21
8 96.48 0.79 20 95.47 1.30
9 97.02 1.28 21 97.38 0.88
10 95.55 1.14 22 96.85 1.43
11 96.29 1.37 23 96.64 1.59
68
12 96.80 1.40 24 96.87 1.52

ANSWER:
2317
x= = 96.54, s = 1.264, and a6 = .952
24
s 1.264
Since x �3 � = 96.54 �3 = 96.54 �1.63 , then the control limits are: LCL = 94.91,
an n .952 6
and UCL = 98.17. The value of x on the 22nd day lies above the UCL, so the process appears to be
out of control at that time.
74. Consider the control chart based on control limits m0 �2.575s / n .
a. What is the ARL when the process is in control?

b. What is the ARL when n = 4 and the process mean has shifted to m = m0 + s ?
c. How do the values of parts (a) and (b) compare to the corresponding values for a 3-sigma
chart?
ANSWER:
� 2.575s 2.575s �
a. P �m0 - < X < m0 + when m = m0 �
� n n �
= P ( -2.575 < Z < 2.575 ) = .99 T
the probability that a point falls outside the limits is then .01 and ARL = 1/ .01 = 100.
b. P = P(a point is outside the limits

� 2.575s 2.575s �
=1- P �m0 - < X < m0 + when m = m0 + s �
� n n �
(
= 1 - P -2.575 - n < Z < 2.575 - n )
= 1 - P ( -4.575 < Z < .575) �P (-4.58 < Z < .58) = .719 - .50 = .219.
Thus ARL = 1/ .219 = 4.57
c. For a 3-sigma chart, P = 1 - P (-3 �Z �3) = 1 - [F (3) - F (-3)] = 1 - (.9987 - .0013) = .0026 ,
so ARL = 1/ .0026 �385 for an in-control process. When m = m0 + s , the probability of an
out-of-control point is 1 - P( -3 - 2 < Z < 1) = 1 - P( Z < 1) = .1587, so ARL = 1/ .1587 = 6.30.
Section 16.3
75. A manufacturer of dustless chalk instituted a quality control program to monitor chalk density. The
sample standard deviations of densities of n = 8 chalk specimens, were as follow:
.165 .231 .073 .165 .292 .371 .179 .234

.408 .207 .170 .249 .296 .138 .111 .076
.224 .335 .116 .204 .250 .232 .342 .307
Calculate limits for an S chart, and check for out-of-control points. If there is an out-of-control
point, delete it and repeat the process.
69
CHAPTER SIXTEEN
ANSWER:
�si = 5.375 and s = 5.375 / 24 = .224.
With a5 = .940 , the expression for LCL will be negative, in which case LCL = 0 should be used.
The upper control limit is UCL = s + 3s �1 - an2 / an =
3(.224) 1 - (.940) 2
.224 + = .224 + .2293 = .4533.
.940
Every si is between these limits, so the process appears to be in control with respect to variability.
76. Subgroups of power supply units are selected once each hour from an assembly line, and the high-
voltage output of each unit is determined.
a. Suppose the sum of the resulting sample ranges for 30 subgroups, each consisting of four
units, is 84. Calculate control limits for an R chart.
b. Repeat part (a) if each subgroup consists of eight units and the sum is 105.
ANSWER:
a. r = 84 / 30 = 2.8, b4 = 2.058, and c4 = .88.
Since n = 4 (which is �6), the expression for LCL will be negative, in which case, LCL = 0
should be used.
3(.88)(2.8)
The upper control limit is UCL = r + 3cn r / bn = 2.8 + = 2.8 + 3.59 = 6.39.
2.058
b. r = 105 / 30 = 3.5, b8 = 2.844, and c8 = .82.
3(.82)(3.5)
The control limits are r �3cn r / bn = 3.5 � = 3.5 �3.06 ; therefore LCL= .47 and
2.844
UCL = 6.53
Section 16.4
77. On each of the previous 25 days, 100 electronic devices of a certain type were randomly selected
and subjected to a severe heat stress test. The total number of items that failed to pass the test was
570.
a. Determine control limits for a 3-sigma p chart.

b. The highest number of failed items on a given day was 40, and the lowest number was 12.
Does either of these correspond to an out-of-control point? Explain.
ANSWER:
�x 570
�x i = 570, from which p =
nk
i
=
(100)(25)
= .228
p (1 - p) (.228)(.772)
a. The control limits are p �3 = .228 �3 = .228 �.126 ; therefore LCL
n 100
= .102 and UCL = .354
b. 12 / 100 =.12, which is between the limits, but 40 / 100 =.40, which exceeds the upper control
limit and therefore generates an out-of-control signal.
70
78. A sample of ROM computer chips was selected on each of 30 consecutive days, and the number of
nonconforming chips on each day was as follows:
30 16 17 22 19 18 16 23 13 21
18 19 13 25 31 17 12 21 15 29
11 19 25 18 38 20 8 26 12 25
Determine control limits for a 3-sigma p chart and specify any out-of-control points.
ANSWER:
�x 597
�x i = 597, from which p =
nk
i
=
(200)(30)
= .0995.
p (1 - p ) (.0995)(.9005)
The control limits are p �3 = .0995 �3 = .0995 �.0635 ; therefore
n 200
LCL = .036 and UCL = .163.
The smallest xi is x7 = 8, with pˆ 7 = 8 / 200 = .04 , which is between the control limits. The largest
xi is x5 = 38, with pˆ 5 = 38 / 200 = .19 . This exceeds UCL, so an out-of-control signal is generated.
This is the only such signal, since the next largest xi is x25 =31, with pˆ 25 = 31/ 200 = .155 < UCL.
79. When n = 180, what is the smallest value of p for which the LCL in a 3-sigma p chart is positive?
ANSWER:
p (1- p)
. After squaring both sides, then .20 p > p ( 1 - p ) . This implies
2
LCL > 0 when p > 3
n
that 20 p > ( 1 - p ) , i.e. 21p > 1 � p = 1/ 21 = .0476.
80. The accompanying observations are numbers of defects in 25 1-square-yard specimens of woven
fabric of a certain type: 3, 7, 5, 3, 4, 2, 8, 4, 3, 3, 6, 6, 2, 3, 2, 4, 7, 3, 2, 3, 4, 1, 5, 4, 6. Determine
control limits for a 3-sigma c chart for the number of defects, and discuss the behavior of the
chart.
ANSWER:
�xi = 100, x = 4.0, and the control limits are x �3 x =4.0 �6.0 Thus LCL = 0 and UCL = 10..
Because no xi exceeds 10, the process is judged to be in control.
81. For what x values will the LCL in a 3-sigma c chart be negative?
ANSWER:
x - 3 x < 0 is equivalent to x < 3, i.e. x < 9.
Section 16.5
82. Containers of a certain treatment for septic tanks are supposed to contain 16 oz of liquid. A
sample of five containers is selected from the production line once each hour and the sample
average content is determined. Consider the following results:
71
CHAPTER SIXTEEN
15.993 16.052 16.067 15.913 16.031 16.061 15.983 15.900

16.039 16.075 16.040 15.936 16.033 15.961 16.056
Using D = .10 and h = .20, employ the computational form of the CUSUM procedure to
investigate the behavior of this process.
ANSWER:
D
m0 = 16, k = = 0.05, h = .20, di = max (0, di -1 + ( xi - 16.05)),
2
ei = max(0, ei -1 - ( xi - 15.95)).
i xi - 16, 05 di xi - 15.95 ei
1 -0.057 0 0.043 0
2 0.002 0.002 0.102 0
3 0.017 0.019 0.117 0
4 -0.137 0 -0.037 0.037
5 -0.019 0 0.081 0
6 0.011 0.011 0.111 0
7 -0.067 0 0.033 0
8 -0.150 0 -0.053 0.053
9 -0.011 0 0.089 0
10 0.025 0.025 0.125 0
11 -0.020 0.005 0.080 0
12 -0.114 0 -0.014 0.014
13 -0.017 0 0.083 0
14 -0.089 0 0.011 0
15 0.006 0.006 0.106 0
For no time r is the case that d r > .20 or that er > .20, so no out-of-control signals are generated.
83. The standard deviation of a certain dimension on an aircraft part is .005 cm. What CUSUM
procedure will give an in-control ARL of 600 and an out-of-control ARL of 4 when the mean
value of the dimension shifts by .004 cm?
ANSWER:
Connecting 600 on the in-control ARL scale to 4 on the out-of-control scale and extending to the
D/2 .002
k’ scale gives k’ = .87. Thus k ' = = from which n = 2.175 � n = 4.73 = s.
s / n .005 / n
Then connecting .87 on the k’ scale to 600 on the out-of-control ARL scale and extending to h’
�s � �.005 �
gives h’ = 2.8, so h = � � (2.8) = � � (2.8) = .00626.
�n� � 5 �
84. When the out-of-control ARL corresponds to a shift of 1 standard deviation I the process mean,
what are the characteristics of the CUSUM procedure that has ARL of 250 and 4.8 for the in-
control and out-of-control conditions, respectively?
ANSWER:
D/2 s /2 n
= .7 =
In- control ARL = 250, out-of-control ARL = 4.8, from which k � = = .
s/ n s/ n 2
�s �
So n = 1.4 � n = 1.96 �2. Then h ' = 2.85, giving h = � �(2.85) = 2.0153s .
�n�
72
Section 16.6
85. A sample of 50 items is to be selected from a batch consisting of 5000 items. The batch will be
accepted if the sample contains at most one defective item. Calculate the probability of lot
acceptance, P(A), for p = .01, .02,…, .10, and sketch the OC curve.
ANSWER:
50 � 0
� 50 � 1
�
P(A) = P( X �1) = � �p (1 - p ) + � �p (1 - p ) = (1 - p) + 50 p(1 - p)
50 49 50 49
0
� � 1
� �
p .01 .02 .03 .04 .05 .06 .07 .08 .09 .10
P(A) .9106 .7358 .5553 .4005 .2794 .1900 .1265 .0827 .0532 .0338
86. A sample of 100 items is to be selected from a batch consisting of 5000 items. The batch will be
accepted if the sample contains at most two defective items.
a. Calculate the probability of lot acceptance, P(A), for p = .10, .02, …, .05, and sketch the OC
curve.
b. Sketch the OC curve in problem 85 above (with n = 50, and c = 1) and the OC curve in part
(a) of problem 86 (with n = 100, and c = 2) on the same set of axes. Which of the two plans is
preferable (leaving aside the cost of sampling) and why?
ANSWER:
a.
73
CHAPTER SIXTEEN
100 � 0
� �100 � 1 �100 � 2
P(A) = P( X �2) = � �p (1 - p ) + � �p (1 - p ) + � �p (1 - p )
100 99 98
0
� � 1
� � 2
� �
= (1 - p) + 100 p(1 - p ) + 4950 p (1 - p )
100 99 2 98
p .01 .02 .03 .04 .05 .06 .07 .08 .09 .10
P ( X �2) .9206 .6767 .4198 .2321 .1183 .0566 .0258 .0113 .0048 .0019
b.
74
For values of p quite close to 0, the probability of lot acceptance using the plan in problem 85
(with n = 50, and c = 1) is larger than that for the plan in problem 86 (with n = 100, and c = 2),
whereas for larger p the latter plan is less likely to result in an “accept the lot” decision (dividing
point between “close to zero” and “larger p” is someplace between .01 and .02). In this sense, the
former plan in problem 85 is better.
87. Consider the single-sample plan that utilizes n = 50 and c = 1 when N = 2000. Determine the
values of AOQ and ATI for selected values of p and graph each of these against p. Also determine
the value of AOQL.
ANSWER:
50 � 0
� 50 � 1
�
P(A) = P( X �1) = � �p (1 - p ) + � �p (1 - p ) = (1 - p) + 50 p(1 - p)
50 49 50 49
0 �
� 1 �
�
p .01 .02 .03 .04 .05 .06 .07 .08 .09 .10
P(A) .9106 .7358 .5553 .4005 .2794 .1900 .1265 .0827 .0532 .0338
Since AOQ = pP( A), then multiplying each entry in the second row of the above table by the
corresponding entry in the first row gives AOQ as shown in the table below:
p .01 .02 .03 .04 .05 .06 .07 .08 .09 .10
AOQ .0091 .0147 .0167 .0160 .0140 .0114 .0089 .0066 .0048 .0034
ATI = 50 P(A) + 2000 (1-P(A)) = 2000 – 1950 P(A)
p .01 .02 .03 .04 .05 .06 .07 .08 .09 .10
ATI 224.3 565.2 917.2 1219.0 1455.2 1629.5 1753.3 1838.7 1896.3 1934.1
75
CHAPTER SIXTEEN
d d
AOQ = P ( A) = p[(1 - p )50 + 50 p (1 - p ) 49 ]�
�p � �= 0 gives the quadratic equation
dp dp �
48 + 110.91
2499 p 2 - 48 p - 1 = 0, from which p = = .0318, and AOQL = .0318P ( A) �.0167.
4998
76

Quality Control Methods: Fill-in-the-Blank Questions

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Quality Control Methods

Quality Control Methods

ANSWER: Control charts

ANSWER: assignable causes

ANSWER: center line, control limits

ANSWER: out-of-control, assignable courses

ANSWER: increases, decrease

ANSWER: out of control

ANSWER: graphical, computational

ANSWER: kemp nomogram

ANSWER: operating characteristic curve

ANSWER: acceptance quality level, lot tolerance percent defective

ANSWER: average outgoing quality

ANSWER: double-sampling plan, single-sampling plan

37. Which of the following statements are not true?

38. Which of the following statements are not true?

40. Which of the following statements are true?

A. We might think of “natural random variation” as uncontrollable background noise.

41. Which of the following statements are not true?

42. Which of the following statements are not true?

43. Which of the following statements are not true?

44. Which of the following statements are not true?

A. determine x1 , x2 , x3 ,.....; calculated values of the corresponding sample means.

47. Which of the following statements are true?

49. Which of the following statements are true?

A. average of the values s1 , s2 ,....., sk .

A. 1.062 and 3.138

A. 0.0 and 6.73

53. Which of the following statements are not correct?

A. .0236 and .244

A. The center line of the chart is at height 9

57. Which of the following statements are true?

58. Which of the following statements are true?

59. Which of the following statements are true?

60. Which of the following statements are not true?

61. Which of the following statements are not true?

67. Which of the following statements are not true?

Applied and Computational Questions

12 96.80 1.40 24 96.87 1.52

74. Consider the control chart based on control limits m0 �2.575s / n .

a. What is the ARL when the process is in control?

b. P = P(a point is outside the limits

.165 .231 .073 .165 .292 .371 .179 .234

a. Determine control limits for a 3-sigma p chart.

15.993 16.052 16.067 15.913 16.031 16.061 15.983 15.900

ATI = 50 P(A) + 2000 (1-P(A)) = 2000 – 1950 P(A)

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