Process Management, Analysis, and Improvement (quality control problem)

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Students will construct a UCL and LCL charts / graphs using the HW5 SPC data. The slides walks you through the process – make sure you take time to read the notes provided with the slides (download the slides to view instructor notes).To start – Download the spreadsheet with the data and begin finding X-bar and Range – For this exercise – n = 5 – Use the Chart in the Slides to find the constant (A2, D2, D3) – I believe it is SLIDE 27 in Module 13 – Quality Control..you SHOULD CREATE 2 TABS – First Tab is for Q#1 – data and control chart / graph and Second Tab for Q#3 – data and control chart / graph for after adjustment.Observation
Shift
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Operator
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Sample
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1
30,046
29,972
30,046
29,997
30,018
29,973
29,977
30,065
29,852
30,042
30,028
29,955
30,040
30,007
29,979
30,073
29,995
29,994
29,989
30,021
29,879
30,043
29,969
29,899
30,029
30,046
29,993
30,057
30,004
29,995
2
29,978
29,966
30,004
29,997
29,922
29,990
30,013
30,012
29,978
29,976
29,999
29,984
29,965
30,024
30,007
29,998
29,966
29,982
29,952
30,048
29,882
30,021
30,000
29,875
30,011
30,006
29,991
30,032
30,049
30,000
3
30,026
29,964
30,028
29,980
29,992
29,985
30,042
30,021
29,964
30,021
30,022
29,977
30,001
29,987
30,000
30,027
29,996
29,998
29,941
30,037
29,990
29,963
29,968
29,980
30,017
30,039
29,984
29,979
29,980
29,922
4
29,986
29,942
29,986
30,000
30,008
29,991
30,001
30,024
29,896
29,996
29,942
30,008
29,975
29,951
30,042
29,986
30,039
30,040
30,012
29,985
29,971
29,993
29,976
29,878
30,000
29,991
30,022
30,027
30,000
29,984
5
29,961
30,025
30,027
30,034
30,053
30,004
29,962
30,037
29,876
30,042
29,998
30,033
29,970
29,994
30,000
30,011
29,976
30,017
29,984
30,005
29,953
30,006
29,973
29,877
30,000
29,970
30,010
30,033
29,986
29,968
SCM 424: Process Management, Analysis, and Improvement
Homework Assignment 5 – SPC
This assignment is to be submitted online via Canvas by the due date and time listed on the
syllabus. You should submit two files online. One file should be an Excel workbook
containing all relevant and completed Excel worksheet(s) (with relevant cells highlighted)
associated with the assignment. The second file should be an appropriately formatted PDF
document containing all the relevant answers to Questions 1A–1D, including charts associated
with the assignment, and references to any highlighted cells in the Excel spreadsheet. All charts
and the written assignment should be formatted to look professional. Points will be deducted for
formatting related issues. In the following questions, whenever x-bar and r-charts are required,
use the A2, D3, D4 method of computing the control limits.
Shift
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2
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1
2
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1
2
3
1
2
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1
2
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1
2
3
1
2
3
1
2
3
Operator
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Sample
1
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13
14
15
16
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21
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30
1
30.046
29.972
30.046
29.997
30.018
29.973
29.977
30.065
29.852
30.042
30.028
29.955
30.040
30.007
29.979
30.073
29.995
29.994
29.989
30.021
29.879
30.043
29.969
29.899
30.029
30.046
29.993
30.057
30.004
29.995
2
29.978
29.966
30.004
29.997
29.922
29.990
30.013
30.012
29.978
29.976
29.999
29.984
29.965
30.024
30.007
29.998
29.966
29.982
29.952
30.048
29.882
30.021
30.000
29.875
30.011
30.006
29.991
30.032
30.049
30.000
Observation
3
4
30.026
29.986
29.964
29.942
30.028
29.986
29.980
30.000
29.992
30.008
29.985
29.991
30.042
30.001
30.021
30.024
29.964
29.896
30.021
29.996
30.022
29.942
29.977
30.008
30.001
29.975
29.987
29.951
30.000
30.042
30.027
29.986
29.996
30.039
29.998
30.040
29.941
30.012
30.037
29.985
29.990
29.971
29.963
29.993
29.968
29.976
29.980
29.878
30.017
30.000
30.039
29.991
29.984
30.022
29.979
30.027
29.980
30.000
29.922
29.984
5
29.961
30.025
30.027
30.034
30.053
30.004
29.962
30.037
29.876
30.042
29.998
30.033
29.970
29.994
30.000
30.011
29.976
30.017
29.984
30.005
29.953
30.006
29.973
29.877
30.000
29.970
30.010
30.033
29.986
29.968
1
Dean Door Corporation (DDC) manufactures steel and aluminum exterior doors for commercial
and residential applications. The manufacturing operation operates three shifts per day to handle
demand. Over the past month, DDC has been receiving complaints about excessive gaps between
the door and the frame. The plant manager suspects the capability of a critical cutting operation
may be the source of the problem. The nominal specification for this cutting operation is 30.000
inches with a tolerance of 0.125 inches. To investigate the problem, five consecutive door panels
were inspected in the middle of each shift over a 10-day period and the dimensions of the cut were
recorded. This data is shown in the table above.
1. (15 points) Construct the appropriate x-bar and R control chart(s) for the data in the table
using 3 sigma control limits. Note: put the appropriate sample measures from all three
workers on the same chart in the order in which the observations were taken (i.e., you
should have one connected line on the graph containing 30 observations).
2. (5points) If the process is in control, explain why. If the process is out of control, explain
why and provide likely causes based on the data provided. In addition, explain how any
special causes found might be eliminated.
3. (5 points) You now wish to examine the capability of the process. If the process is out of
control, first remove any samples that correspond to data associate with the special causes
and recompute the control chart(s). Include a copy of these revised charts with the
assignment.
4. (5 points) Compute CPK, indicate whether the process is capable and explain why or why
not. DDC uses a critical value of 1.33 when determining process capability.
2
Observation
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Operator
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
Jordan
Dana
Terry
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Dana
Terry
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Dana
Terry
Jordan
Dana
Sample
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1
30.046
29.972
30.046
29.997
30.018
29.973
29.977
30.065
29.852
30.042
30.028
29.955
30.040
30.007
29.979
30.073
29.995
29.994
29.989
30.021
29.879
30.043
29.969
29.899
30.029
30.046
29.993
30.057
30.004
29.995
2
29.978
29.966
30.004
29.997
29.922
29.990
30.013
30.012
29.978
29.976
29.999
29.984
29.965
30.024
30.007
29.998
29.966
29.982
29.952
30.048
29.882
30.021
30.000
29.875
30.011
30.006
29.991
30.032
30.049
30.000
3
30.026
29.964
30.028
29.980
29.992
29.985
30.042
30.021
29.964
30.021
30.022
29.977
30.001
29.987
30.000
30.027
29.996
29.998
29.941
30.037
29.990
29.963
29.968
29.980
30.017
30.039
29.984
29.979
29.980
29.922
4
29.986
29.942
29.986
30.000
30.008
29.991
30.001
30.024
29.896
29.996
29.942
30.008
29.975
29.951
30.042
29.986
30.039
30.040
30.012
29.985
29.971
29.993
29.976
29.878
30.000
29.991
30.022
30.027
30.000
29.984
5
29.961
30.025
30.027
30.034
30.053
30.004
29.962
30.037
29.876
30.042
29.998
30.033
29.970
29.994
30.000
30.011
29.976
30.017
29.984
30.005
29.953
30.006
29.973
29.877
30.000
29.970
30.010
30.033
29.986
29.968

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