BMM 3643

ASSIGNMENT 1

ASSIGNMENT 1
BMM 3633 INDUSTRIAL ENGINEERING
Prepared by: Puan Nurul Shahida Mohd Shalahim
Instruction: This assignment consists of two sections. Answer ALL
questions.
Section A Multiple Choice Questions (20 Marks)
1. Who is known as Father of Quality Control Circle (QCC)?
a. Juran
b. Deming
c. Ishikawa
d. Pareto
2. If Q is quality, P is performance, E is expectations, then what do
you understand by Q > 1?
a. Performance is less than expectations
b. Performance is more than expectations
c. Performance is at par
d. None of the above
3. A defect is known as
a. Physical damage
b. Aesthetic non conformance
c. Non-conformance to parameter
d. All above
4. Process flow diagram is a tool to
a. Audit process
b. Identify potential trouble spots
c. Locate control activities
d. All above
5. The tool used to show movement of product is
a. Histogram
b. Control chart
c. Process flow chart
d. Scatter diagram
6. Skewness in the data is presented by
a. Process flow chart
b. Histogram
c. Pareto diagram
d. Cause and effect diagram

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ASSIGNMENT 1

7. Which tool is also known as 80-20 rule?

a. Histogram
b. Pareto diagram
c. Cause and effect diagram
d. Scatter diagram
8. Which tool is also known as Fishbone diagram?
a. Pareto diagram
b. Scatter diagram
c. Ishikawa diagram
d. Histogram
9. If the value of r = 0.92, then the two variables have
a. High degree of positive correlation
b. Low degree of positive correlation
c. High degree of negative correlation
d. Low degree of negative correlation
10.
a.
b.
c.
d.

For mean chart, UCL is

Mean + Std. dev.
Mean +3Std. dev.
Mean Std. dev.
Mean 3Std. dev.

11.
a.
b.
c.
d.

For range chart, UCL is

Mean + Std. dev.
Range + Std. dev.
Range + 3Std. dev.
Mean + 3Std. dev.

12.
a.
b.
c.
d.

Accuracy is
Closeness of individual data points
Closeness of data points to target value
Closeness of mean value to target value
None of the above

13.
a.
b.
c.
d.

Precision is
Closeness of individual data points
Closeness of data points to target value
Closeness of mean value to target value
None of the above

14.
a.
b.
c.
d.
e.

Which is NOT a cost of quality?

Prevention cost
External failure
Extended service contracts
Internal failure
Appraisal costs

BMM 3643

15.
a.
b.
c.
d.

ASSIGNMENT 1

An internal failure cost is

Warranty costs
Cost of returns
Cost of prequalifying suppliers
Scrap and rework costs

16. In statistical process control (SPC) chart, special or assignable

causes of variation
a. Are outside, non-random problems such as breakdown of
machinery, material variation, or human error.
b. Are intrinsic to the process and will always be there unless the
process is changed.
c. Have everything to do with the underlying process and can
only be eliminated by changing the process.
d. Are of secondary importance in quality control procedures
used to detect and eliminate variation.
e. Can be present in a process that is fully capable of meeting
specifications consistently.
17.
a.
b.
c.
d.

The best type of inspection to use is:

100 percent inspection
Carried out by a commercial testing laboratory
Dependent on the nature of the purchase
Sequential sampling

18. ISO 9000:2008

a. Provides common quality standards across all sectors
b. Was established by the International Supply Organizational to
focus quality efforts on supplier relationships
c. Provides guidance for continuous improvement of quality
management systems to achieve sustained customer
satisfaction
d. Was developed and first issued in the US and later adopted
worldwide
e. Was designed to recognize organizations that excel in quality
achievements and quality management
19.
a.
b.
c.
d.

TQM tools include

Kaizen
Continuous improvement
Quality function deployment (QFD)
a, b and c

20.
a.
b.
c.
d.

All quality improvement programs are initiated by a desire to:

eliminate incoming inspection
lower costs
increase prices
reduce incoming inspection

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ASSIGNMENT 1

e. beat the competition

Section B Subjective Questions
1. The Specialty Chemical Company is concerned about the number
of customer complaints about the following:

Customer received improperly labelled shipments

Customer received improperly packaged shipments
Customer received off-specification shipments
Customers shipment was late

The supervisor in charge of loading and shipping investigates the

complaints over a 6-month period and finds the complaints
include all forms of loaded and shipped products. There are
complaints about rail cars, tank trucks, tote bins, and barrels. To
bring about a quick reduction in complaints and focus on the
major problem areas, the supervisor decided to use several
quality tools to analyse the problem. He gathered the data and
placed in Table 1 below.
Table 1 Errors in loading and shipping
Type of Shipment
Tank trucks
Rail cars
Tote bins
Drums

Number of Errors
4
2
12
18

From the data, please:

a)
b)
c)
d)

Construct histogram (3 Marks)

Discuss the depicted histogram (3 Marks)
Construct Pareto chart (4 Marks)
From the Pareto chart, what is the greatest problem they
had?
(2 Marks)
e) From the Pareto chart, where should he concentrate their
efforts for improvement? (3 Marks)

BMM 3643

ASSIGNMENT 1

2. A recent survey of 519 adults who flew in the past year with TH
airlines found the following number of complaints about flying.
The complaints are summarized in Table 2 below.
Table 2 Complaints about flying
Complaints
Cramped seats
Cost
Dislike of flying
Security measures
Poor service
Connecting flight problems
Overcrowded planes
Waiting time
Food
Lost luggage
Others

Number
45
16
57
119
12
8
42
57
7
7
51

From the data, please:

a) Develop a Pareto chart summarizing these responses. Your
analysis should be included with the passengers who do
not complaint at all. (5 Marks)
b) Use the four Ms method to construct a fish-bone diagram
for the 10 specific categories of dislikes (exclude other
and no complaints). (5 Marks)
c) If you were managing an airline, what are the three specific
issues would you tackle to improve customer service?
Please justify.
(5 Marks)
3. Discuss the types of variations given below that might occur in
manufacturing process:
a)
b)
c)
d)

Equipment (2 Marks)
Material (2 Marks)
Environment (2 Marks)
Operator (2 Marks)

BMM 3643

ASSIGNMENT 1

4. Table 3 gives the average and range of weight in kilograms (kg)

for the tensile test on an improved PETLIN bag. The subgroup
size used is 4.
a) Determine the trial control line and control limits, and plot the
suitable control chart. (8 Marks)
b) Discuss what you observe from the chart. (4 Marks)
Table 3 Weight for PETLIN bag
Subgroup
number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

476
466
484
466
470
494
486
496
488
482
498
464
484
482
506

32
24
32
26
24
24
28
23
24
26
25
24
24
22
23

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ASSIGNMENT 1

5. A team in an accounting group has been working on improving

the processing of invoices. The team is trying to reduce the cost
of processing invoices by decreasing the fraction of invoices with
errors. The team developed the following operational definition
for a defective invoice: an invoice is defective if it has incorrect
price, incorrect quantity, incorrect coding, incorrect address, or
incorrect name. The team decided to pull a random sample of
100 invoices per day. If the invoice had one or more errors it was
defective. The data from the last 25 days are given in Table 4.
a) Construct a p chart. (10 Marks)
b) Discuss what you observe from the chart. (5 Marks)
Table 4 Investigation on Invoices
Day
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Invoices
Inspected (n)
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100

Number
Defective (np)
22
33
24
20
18
24
24
29
18
27
31
26
31
24
22
22
29
31
21
26

Fraction
Defective (p)
0.22
0.33
0.24
0.20
0.18
0.24
0.24
0.29
0.18
0.27
0.31
0.26
0.31
0.24
0.22
0.22
0.29
0.31
0.21
0.26
7

BMM 3643

21
22
23
24
25

ASSIGNMENT 1

100
100
100
100
100

24
32
17
25
21

0.24
0.32
0.17
0.25
0.21

6. Wafiq Wafer Enterprise would like to investigate the

nonconforming wafers produced in the factory. As a manager,
Wafiq has appointed you to inspect 25 successive wafers, each
containing 100 chips. Here the wafer is the inspection unit. The
observed number of defects is depicted in Table 5.
a) Plot a c chart. (10 Marks)
b) Discuss what you observe from the chart. (5 Marks)
Table 5 Data on Investigated Wafers
Wafer Number Wafer Number
Number
of
Number
of
Defects
Defects
1
2
3
4
5
6
7
8
9
10
11
12
13

16
14
28
16
12
20
10
12
10
17
19
17
14

14
15
16
17
18
19
20
21
22
23
24
25

16
15
13
14
16
11
20
11
19
16
31
13