ESSAY (100 marks) Instruction: This section consists of SIX (6) essay questions.

Answer only FOUR (4) questions. QUESTION 1

(a)

Give the definitions for quality and zero defect. (3 marks)

(b)

Inspection of products is important to ensure the products quality level. State and elaborate TWO (2) types of products inspection. (6 marks)

(c)

In a manufacturing steel industry, steel rods are produced through the pultrusion process. The average of steel rod diameter is 3.20 cm and standard deviation is 0.05 cm. The acceptance level is 3.200.06 cm. Based on this case, sketch and label a normal curve. (4 marks)

Calculate: i. The percentage of rejected rods. (4 marks)

ii.

The percentage of the rods reworked.

(4 marks)

iii.

The percentage of accepted rods.

(4 marks)

Pages 2 of 8

QUESTION 2

(a)

Define the following terms:

i. ii. iii.

Control Charts for Variables Assignable causes variation Random variation

(3 marks) (3 marks) (3 marks)

(b)

Define process capability (Cp) and illustrate cases where process variability exceeds specifications. (4 marks)

(c)

Table 1 shows some sampling data. By using the table,

i. ii. iii.

Determine the mean and range (X and R). Determine the upper and lower control limit (UCL and LCL). Draw a control chart from the data.

(4 marks) (4 marks) (4 marks)

TABLE 1 Sample number 1 2 3 4 5 6 7 8 9 10 28.28 26.92 28.46 32.43 28.84 30.75 31.26 31.25 31.42 32.20 Observations (mm) 33.95 27.66 28.30 26.10 30.52 33.00 24.29 28.58 35.80 32.02 30.47 31.47 29.00 29.84 32.24 28.08 35.46 35.01 33.61 32.71 28.87 29.67 31.14 37.20 30.47 26.20 28.41 31.24 27.82 29.38
Pages 3 of 8

QUESTION 3

(a)

Differentiate between defect and defective and briefly describe types of attributes control charts related to each of them. (10 marks)

(b)

Define the word attributes by giving suitable examples. (5 marks)

(c)

Table 2 represents the observed number of defects from an inspection of 30 successive chocolate wafers, each containing 100 chips. determine : i. The average number of defects (c) (4 marks) ii. The upper and lower control limits ( UCL and LCL) (6 marks) Number of Chocolate Wafers 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 TABLE 2 Number of defects Number of Chocolate Wafers 19 16 17 17 14 18 16 19 15 20 13 21 14 22 16 23 11 24 20 25 15 26 13 27 10 28 15 29 16 30 Number of defects 16 14 28 16 12 20 10 12 10 17 10 12 13 18 11

Pages 4 of 8

QUESTION 4

(a)

Give TWO (2) types of Control Chart. (2 marks)

(b)

Explain how to choose a control chart suitable for a specific data. (4 marks)

(c)

Table 3 is a data compilation of the length of steel bars. TABLE 3

Date

Time 9.00 10.00 11.00 12.00 1.00 2.00 3.00 9.00 10.00 11.00 12.00 1.00 2.00 3.00 9.00 10.00 11.00 12.00 1.00 2.00 3.00

1/8/05

No. of Inspected Bars (mm) B1 B2 B3 B4 5.85 5.65 5.65 5.70 5.75 5.85 5.75 5.85 5.80 5.80 5.75 5.70 5.65 5.75 5.60 5.70 5.75 5.70 5.65 5.80 5.60 5.75 5.65 5.70 5.65 5.80 5.60 5.60 5.80 5.75 5.80 5.65 5.85 5.60 5.70 5.80 5.75 5.80 5.65 5.85 5.80 5.60 5.75 5.85 5.80 5.65 5.75 5.60 5.80 5.80 5.75 5.80 5.65 5.85 5.60 5.70 5.85 5.75 5.80 5.65 5.85 5.70 5.60 5.80 5.75 5.80 5.65 5.85 5.60 5.65 5.65 5.75 5.80 5.65 5.75 5.60 5.70 5.80 5.75 5.80 5.65 5.85 5.80 5.60

Mean

Range

2/8/05

3/8/05

Pages 5 of 8

i. ii. iii. iv.

Determine the mean and range (X and R). Determine the central line and control limits. Plot the points of the chart. Analyze the plotted points to determine if the process is in control. Give a reason for your answer.

(4 marks) (6 marks) (5 marks)

(4 marks)

Pages 6 of 8

QUESTION 5

(a)

Differentiate producers risk and consumers risk. (4 marks)

(b)

In sampling inspection products that do not meet specifications would be rejected. Explain in detail THREE (3) actions that are usually taken against the rejected lot. (9 marks)

(c)

Using Table 4, inspector needs to determine the Single Sampling Plans for the following information: TABLE 4 INSPECTION LEVEL i) II ii) I iii) III INSPECTION Tightened Normal Reduced AQL 1.5% 65% 0.40% LOT SIZE 1,400 115 160,000 (9 marks)

(d)

Explain the sampling plan determined in QUESTION 5 (c) iii. if 6 nonconforming units are found in the sample. (3 marks)

Pages 7 of 8

QUESTION 6

(a)

i.

State FOUR (4) types of quality cost.

(4 marks)

ii.

Explain TWO (2) types of quality cost.

(4 marks)

iii.

Draw and label the curve of quality cost.

(2 marks)

(b)

i. iii.

State the uses of Pareto Diagram. Using Table 5, construct the Pareto Diagram and discuss the results. TABLE 5 Types of defections Scratch Broken Color not uniform Short mould Flashing Pin hole etc

(2 marks)

(10 marks)

Number of nonconforming units 42 20 108 10 35 15 5

(c)

Give the terms for ISO 9000:2000 listed below. i. ii. iii. ISO 9000 ISO 9001 ISO 9004 ( 3 marks)

Pages 8 of 8